Iowa State University Capstones, Theses and Graduate Theses and Dissertations Dissertations 2017 Modeling of filament deposition rapid prototyping process with a closed form solution Steven Leon Devlin Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/etd Part of the Other Education Commons Recommended Citation Devlin, Steven Leon, "Modeling of filament deposition rapid prototyping process with a closed form solution" (2017). Graduate Theses and Dissertations. 16121. https://lib.dr.iastate.edu/etd/16121 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Graduate Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. Modeling of filament deposition rapid prototyping process with a closed form solution by Steven Leon Devlin A dissertation submitted to the graduate faculty in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Major: Industrial and Agricultural Technology Program of Study Committee: David Grewell, Major Professor Matthew Charles Frank Steven A. Freeman Gretchen Ann Mosher W. Robert Stephenson The student author, whose presentation of the scholarship herein was approved by the program of study committee, is solely responsible for the content of this dissertation. The Graduate College will ensure this dissertation is globally accessible and will not permit alterations after a degree is conferred. Iowa State University Ames, Iowa 2017 Copyright © Steven Leon Devlin, 2017. All rights reserved. ii DEDICATION This dissertation is dedicated to my parents, the late Judith L. Devlin and Leon G. Devlin, who taught me to push beyond life’s expectations and my family, Colleen E. Devlin, Rebecca E. Devlin, and Connor S. Devlin, who give my life purpose iii TABLE OF CONTENTS Page LIST OF FIGURES ................................................................................................... vi LIST OF TABLES ..................................................................................................... vii NOMENCLATURE .................................................................................................. viii ACKNOWLEDGMENTS ......................................................................................... x ABSTRACT………………………………. .............................................................. xii CHAPTER 1 INTRODUCTION: GENERAL INTRODUCTION ...................... 1 Introduction to Research ...................................................................................... 1 Interfacial Healing ......................................................................................... 5 Squeeze Flow ........................................................................................ 6 Thermal Model...................................................................................... 11 Purpose of Research ............................................................................................. 17 Research Questions .............................................................................................. 19 Measurement and Methodology .......................................................................... 20 Statistical Analysis ............................................................................................... 23 Organization of Dissertation ................................................................................ 31 References ......................................................................................................... 31 CHAPTER 2 LITERATURE REVIEW ............................................................... 34 Growing Interest .................................................................................................. 34 Technology Adoption .......................................................................................... 37 Equipment Research ............................................................................................ 39 Experimental Additive Manufacturing Methods ................................................. 48 Standardization .................................................................................................... 50 References ......................................................................................................... 54 CHAPTER 3 PROCESS PARAMETERS AND PRODUCT STRENGTH FOR FUSED DEPOSITION MODELING ........................................................................ 58 Abstract ......................................................................................................... 58 Introduction Developing Industry – Additive Manufacturing ............................. 59 Benefits of Fused Deposition Modelling for functional parts ............................. 60 Experimental Investigation .................................................................................. 62 Materials and Methods ......................................................................................... 64 Results and Discussion ........................................................................................ 65 Figures ......................................................................................................... 67 Tables ......................................................................................................... 72 iv Acknowledgments................................................................................................ 73 References ......................................................................................................... 73 CHAPTER 4 EXPERIMENTAL DETERMINATION OF PLA WELD STRENGTH IN FUSED FILAMENT FABRICATION PARTS ............................. 75 Abstract ......................................................................................................... 75 Introduction Developing Industry – Additive Manufacturing ............................. 76 Fused Filament Fabrication for functional parts .................................................. 77 Experimental Investigation .................................................................................. 78 Materials and Methods ......................................................................................... 78 Data Analysis ....................................................................................................... 81 Discussion ......................................................................................................... 83 Conclusion ......................................................................................................... 85 Figures ......................................................................................................... 86 References ......................................................................................................... 92 Appendix ......................................................................................................... 92 CHAPTER 5 EXPERIMENTAL AND NUMERICAL EVALUATION OF 3D PRINTING FILAMENT WELDING STRENGTH .................................................. 97 Abstract ......................................................................................................... 97 Introduction ......................................................................................................... 98 Experimental Work .............................................................................................. 101 Microscopic Analysis........................................................................................... 103 Numerical Modeling ............................................................................................ 106 Results and Discussion ........................................................................................ 108 Conclusions ......................................................................................................... 114 References ......................................................................................................... 115 CHAPTER 6 A CLOSED FORM SOLUTION FOR PREDICTING FINAL PART STRENGTH OF FUSED DEPOSITION MODELING ................................. 117 Abstract ......................................................................................................... 117 Introduction ......................................................................................................... 118 Interfacial Healing and Squeeze Flow ................................................................. 120 Energy Flow Model ............................................................................................. 125 Experimental Procedures – Fused Filament Extrusion ........................................ 127 Results and Discussion ........................................................................................ 129 Model Validation ................................................................................................. 131 Conclusions ......................................................................................................... 132 References ......................................................................................................... 133 v CHAPTER 7 GENERAL REVIEW OF CONCLUSIONS AND RECOMENDATIONS .......................................................................................