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Computational Fluid Dynamics (CFD) Analysis of 3D Printer Nozzle Designs

Year 2024, , 1233 - 1246, 31.12.2024
https://doi.org/10.17798/bitlisfen.1543679

Abstract

Additive manufacturing, particularly 3D printing, has gained significant attention recently due to its flexibility, precision, and sustainability. Among the various 3D printing technologies, Fused Deposition Modeling (FDM) stands out as one of the most popular due to its affordability, ease of use, and print quality. However, a major drawback of FDM-based 3D printers is their relatively low print resolution. One of the key factors influencing print quality is the nozzle design, especially its geometry. As a result, numerous studies in literature have focused on improving 3D printing performance by optimizing nozzle design. In this study, we investigated the effects of nozzle geometry from a Computational Fluid Dynamics (CFD) perspective, examining three aspects: die angle, outlet size, and outlet shape. The CFD analysis revealed that the die angle primarily influences the shear stress within the nozzle, while the outlet size has a significant impact on velocity and pressure difference. The outlet shape affects shear stress, velocity, and pressure difference to a lesser extent than the die angle and size.

Ethical Statement

The study is complied with research and publication ethics.

Thanks

The authors would like to acknowledge Abdullah Gul University for giving us an opportunity to work together.

References

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  • [25] M. Temirel, C. Hawxhurst, and S. Tasoglu, "Shape Fidelity of 3D-Bioprinted Biodegradable Patches," Micromachines (Basel), vol. 12, no. 2, Feb 13 2021, doi: 10.3390/mi12020195.
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  • [42] A. L. Rutz, K. E. Hyland, A. E. Jakus, W. R. Burghardt, and R. N. Shah, "A multimaterial bioink method for 3D printing tunable, cell‐compatible hydrogels," Advanced Materials, vol. 27, no. 9, pp. 1607-1614, 2015.
  • [43] N. Hasan and Y. B. Mathur, "Optimizing the Design of Earth Air Tunnel Heat Exchanger for Cooling in Summer Season," International Multidisciplinary Mulitilingual E-Journal, vol. 5, no. 1, pp. 19-29.
Year 2024, , 1233 - 1246, 31.12.2024
https://doi.org/10.17798/bitlisfen.1543679

Abstract

References

  • [1] V. K. Wong and A. Hernandez, "A Review of Additive Manufacturing," ISRN Mechanical Engineering, vol. 2012, pp. 1-10, 2012, doi: 10.5402/2012/208760.
  • [2] N. Shahrubudin, T. C. Lee, and R. Ramlan, "An Overview on 3D Printing Technology: Technological, Materials, and Applications," Procedia Manufacturing, vol. 35, pp. 1286-1296, 2019, doi: 10.1016/j.promfg.2019.06.089.
  • [3] N. Turner, B., Strong, R., & A. Gold, S. (2014). A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid prototyping journal, 20(3), 192-204
  • [4] A. Waldbaur, H. Rapp, K. Länge, and B. E. Rapp, "Let there be chip—towards rapid prototyping of microfluidic devices: one-step manufacturing processes," (in en), 2011/10/10 2011, doi: 10.1039/C1AY05253E.
  • [5] M. Lay, N. L. N. Thajudin, A. A. Z. Hamid, A. Rusli, K. M. Abdullah, and K. R. Shuib, "Comparison of physical and mechanical properties of PLA, ABS and nylon 6 fabricated using fused deposition modeling and injection molding," Composites Part B: Engineering, vol. 176, p. 107341, 2019, doi: 10.1016/j.compositesb.2019.107341.
  • [6] E. I. Basri, A. A. Basri, V. N. Riazuddin, S. F. Shahwir, Z. Mohammad, and K. A. Ahmad, "Computational fluid dynamics study in biomedical applications: a review," International Journal of Fluids and Heat Transfer, vol. 1, no. 2, pp. 2-14, 2016.
  • [7] M. H. Zawawi et al., "A review: Fundamentals of computational fluid dynamics (CFD)," AIP Conference Proceedings, vol. 2030, no. 1, 2024, doi: 10.1063/1.5066893.
  • [8] M. M. Aslam Bhutta, N. Hayat, M. H. Bashir, A. R. Khan, K. N. Ahmad, and S. Khan, "CFD applications in various heat exchangers design: A review," Applied Thermal Engineering, vol. 32, pp. 1-12, 2012, doi: 10.1016/j.applthermaleng.2011.09.001.
  • [9] H. H. Hu, "Chapter 10 - Computational Fluid Dynamics," in Fluid Mechanics (Fifth Edition), P. K. Kundu, I. M. Cohen, and D. R. Dowling Eds. Boston: Academic Press, 2012, pp. 421-472.
  • [10] R. K. Raman, Y. Dewang, and J. Raghuwanshi, "A review on applications of computational fluid dynamics," International Journal of LNCT, vol. 2, no. 6, pp. 137-143, 2018.
  • [11] P. R. Spalart and V. Venkatakrishnan, "On the role and challenges of CFD in the aerospace industry," The Aeronautical Journal, vol. 120, no. 1223, pp. 209-232, 2016.
  • [12] T. Oyinloye and W. Yoon, "Application of Computational Fluid Dynamics (CFD) Simulation for the Effective Design of Food 3D Printing (A Review)," Processes, vol. 9, no. 11, p. 1867, 2021, doi: 10.3390/pr9111867.
  • [13] C.-F. Guo, M. Zhang, and B. Bhandari, "A comparative study between syringe-based and screw-based 3D food printers by computational simulation," Computers and Electronics in Agriculture, vol. 162, pp. 397-404, 2019, doi: 10.1016/j.compag.2019.04.032.
  • [14] M. Temirel, B. Yenilmez, S. Knowlton, J. Walker, A. Joshi, and S. Tasoglu, "Three-Dimensional-Printed Carnivorous Plant with Snap Trap," 3D Printing and Additive Manufacturing, vol. 3, no. 4, pp. 244-251, 2016, doi: 10.1089/3dp.2016.0036.
  • [15] T. Glatzel et al., "Computational fluid dynamics (CFD) software tools for microfluidic applications – A case study," Computers & Fluids, vol. 37, no. 3, pp. 218-235, 2008, doi: 10.1016/j.compfluid.2007.07.014.
  • [16] R. Raj, S. V. V. Krishna, A. Desai, C. Sachin, and A. R. Dixit, "Print fidelity evaluation of PVA hydrogel using computational fluid dynamics for extrusion dependent 3D printing - IOPscience," (in en), Text 2022-02-01 2022, doi: doi:10.1088/1757-899X/1225/1/012009.
  • [17] N. H. Panchal and N. Patel, "ANSYS CFD and experimental comparison of various parameters of a solar still," International Journal of Ambient Energy, vol. 39, no. 6, pp. 551-557, 2018, doi: 10.1080/01430750.2017.1318785.
  • [18] S. O. Alamu, M. J. L. Caballes, Y. Yang, O. Mballa, and G. Chen, "3D Design and Manufacturing Analysis of Liquid Propellant Rocket Engine (LPRE) Nozzle," in Proceedings of the Future Technologies Conference (FTC) 2019: Volume 2, 2020: Springer, pp. 968-980.
  • [19] B. Apacoglu, A. Paksoy, and S. Aradag, "CFD Analysis and Reduced Order Modeling of Uncontrolled and Controlled Laminar Flow Over a Circular Cylinder," Engineering Applications of Computational Fluid Mechanics, vol. 5, no. 1, pp. 67-82, 2014, doi: 10.1080/19942060.2011.11015353.
  • [20] T. Al-Hassan, C. Habchi, T. Lemenand, and F. Azizi, "CFD simulation of creeping flows in a novel split-and-recombine multifunctional reactor," Chemical Engineering and Processing - Process Intensification, vol. 162, 2021, doi: 10.1016/j.cep.2021.108353.
  • [21] A. Tamburini, G. Gagliano, G. Micale, A. Brucato, F. Scargiali, and M. Ciofalo, "Direct numerical simulations of creeping to early turbulent flow in unbaffled and baffled stirred tanks," Chemical Engineering Science, vol. 192, pp. 161-175, 2018, doi: 10.1016/j.ces.2018.07.023.
  • [22] B. Wu and S. Chen, "CFD simulation of non-Newtonian fluid flow in anaerobic digesters," Biotechnol Bioeng, vol. 99, no. 3, pp. 700-11, Feb 15 2008, doi: 10.1002/bit.21613.
  • [23] M. Temirel, S. R. Dabbagh, and S. Tasoglu, "Shape Fidelity Evaluation of Alginate-Based Hydrogels through Extrusion-Based Bioprinting," (in en), Journal of Functional Biomaterials, Article vol. 13, no. 4, p. 225, 2022-11-07 2022, doi: 10.3390/jfb13040225.
  • [24] B. Yenilmez, M. Temirel, S. Knowlton, E. Lepowsky, and S. Tasoglu, "Development and characterization of a low-cost 3D bioprinter," Bioprinting, vol. 13, pp. e00044-e00044, 2019.
  • [25] M. Temirel, C. Hawxhurst, and S. Tasoglu, "Shape Fidelity of 3D-Bioprinted Biodegradable Patches," Micromachines (Basel), vol. 12, no. 2, Feb 13 2021, doi: 10.3390/mi12020195.
  • [26] A. Malekpour and X. Chen, "Printability and cell viability in extrusion-based bioprinting from experimental, computational, and machine learning views," Journal of Functional Biomaterials, vol. 13, no. 2, pp. 40-40, 2022.
  • [27] M. N. U. Fareez, A. A. S. Naqvi, M. Mahmud, and M. Temirel, "Computational Fluid Dynamics (CFD) Analysis of Bioprinting," Advanced Healthcare Materials, 2024, doi: 10.1002/adhm.202400643.
  • [28] N. Zhang and J. Sanjayan, "Extrusion nozzle design and print parameter selections for 3D concrete printing," Cement and Concrete Composites, vol. 137, 2023, doi: 10.1016/j.cemconcomp.2023.104939.
  • [29] F. Kartal and A. Kaptan, "Investigating the Effect of Nozzle Diameter on Tensile Strength in 3D-Printed Printed Polylactic Acid Parts," (in en), Black Sea Journal of Engineering and Science, vol. 6, no. 3, pp. 276-287, July 2023, doi: 10.34248/bsengineering.1287141.
  • [30] D. Kaplan, S. Rorberg, B. M. Chen, and Y. Sterman, "NozMod: Nozzle Modification for Efficient FDM 3D Printing," in Proceedings of the 7th Annual ACM Symposium on Computational Fabrication, ed, 2022.
  • [31] T. Xu, "Various 3D printing materials with different nozzle design in biomedical area," in International Conference on Automation Control, Algorithm, and Intelligent Bionics (ACAIB 2022), 2022, vol. 12253: SPIE, pp. 445-453.
  • [32] "3D Printer Nozzle Design and Its Parameters: A Systematic Review | SpringerLink," 2024, doi: 10.1007/978-981-15-2647-3_73.
  • [33] D. R. Ian Gibson , Brent Stucker, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing | SpringerLink. Springer, 2015.
  • [34] H. Zhang, L. Zhang, H. Zhang, J. Wu, X. An, and D. Yang, "Fibre bridging and nozzle clogging in 3D printing of discontinuous carbon fibre-reinforced polymer composites: coupled CFD-DEM modelling," The International Journal of Advanced Manufacturing Technology, vol. 117, no. 11-12, pp. 3549-3562, 2021, doi: 10.1007/s00170-021-07913-7.
  • [35] H. Zong et al., "Simulation of printer nozzle for 3D printing TNT/HMX based melt-cast explosive," (in En), The International Journal of Advanced Manufacturing Technology, OriginalPaper vol. 119, no. 5, pp. 3105-3117, 2022-01-05 2022, doi: doi:10.1007/s00170-021-08593-z.
  • [36] B. Alphonse, R. Basavaraj, H. Koten, R. Balasubramanian, and S. Umrao, "Comparative design and CFD analysis of 3-D printed acrylonitrile butadiene styrene nozzle aerator for discharge reduction," Thermal Science, vol. 26, no. 2 Part A, pp. 857-869, 2022, doi: 10.2298/TSCI201114155A.
  • [37] O. Hıra, S. Yücedağ, S. Samankan, Y. Ö. Çiçek, and A. Altınkaynak, "Numerical and experimental analysis of optimal nozzle dimensions for FDM printers," Progress in Additive Manufacturing, 2022, doi: 10.1007/s40964-021-00241-y.
  • [38] B. Lizenboim, S. Kenig, and N. Naveh, "The Effect of Nozzle Geometry on the Structure and Properties of 3D Printed Carbon Polyamide Composites," Applied Composite Materials, vol. 31, no. 1, pp. 83-99, 2024, doi: 10.1007/s10443-023-10166-0.
  • [39] S. Han, Y. Xiao, T. Qi, Z. Li, and Q. Zeng, "Design and Analysis of Fused Deposition Modeling 3D Printer Nozzle for Color Mixing," Advances in Materials Science and Engineering, vol. 2017, pp. 1-12, 2017, doi: 10.1155/2017/2095137.
  • [40] Y. Cengel and J. Cimbala, Ebook: Fluid mechanics fundamentals and applications (si units). McGraw Hill, 2013.
  • [41] Q. Sun, G. M. Rizvi, C. T. Bellehumeur, and P. Gu, "Effect of processing conditions on the bonding quality of FDM polymer filaments," Rapid Prototyping Journal, vol. 14, no. 2, pp. 72-80, 2008, doi: 10.1108/13552540810862028.
  • [42] A. L. Rutz, K. E. Hyland, A. E. Jakus, W. R. Burghardt, and R. N. Shah, "A multimaterial bioink method for 3D printing tunable, cell‐compatible hydrogels," Advanced Materials, vol. 27, no. 9, pp. 1607-1614, 2015.
  • [43] N. Hasan and Y. B. Mathur, "Optimizing the Design of Earth Air Tunnel Heat Exchanger for Cooling in Summer Season," International Multidisciplinary Mulitilingual E-Journal, vol. 5, no. 1, pp. 19-29.
There are 43 citations in total.

Details

Primary Language English
Subjects Computational Methods in Fluid Flow, Heat and Mass Transfer (Incl. Computational Fluid Dynamics), Mechanical Engineering (Other)
Journal Section Araştırma Makalesi
Authors

Rasul Hajili 0009-0002-2363-3225

Mikail Temirel 0000-0002-8199-0100

Early Pub Date December 30, 2024
Publication Date December 31, 2024
Submission Date September 4, 2024
Acceptance Date December 29, 2024
Published in Issue Year 2024

Cite

IEEE R. Hajili and M. Temirel, “Computational Fluid Dynamics (CFD) Analysis of 3D Printer Nozzle Designs”, Bitlis Eren Üniversitesi Fen Bilimleri Dergisi, vol. 13, no. 4, pp. 1233–1246, 2024, doi: 10.17798/bitlisfen.1543679.

Bitlis Eren University
Journal of Science Editor
Bitlis Eren University Graduate Institute
Bes Minare Mah. Ahmet Eren Bulvari, Merkez Kampus, 13000 BITLIS