Toz Serme Parametrelerinin Toz Yatağı Kalitesine Etkileri

Year 2024, Volume: 36 Issue: 3, 278 - 289, 26.09.2024

Muhammet Furkan Çoşkun , Recep Önler

https://doi.org/10.7240/jeps.1507109

Abstract

Lazerle toz yatağında füzyon, bağlayıcı püskürtme ve elektron ışını ile ergitme gibi toz yatağı tabanlı yöntemler, tıbbi, havacılık ve enerji gibi çeşitli kritik alanlarda yaygın olarak kullanılmaktadır. Bu işlemlerin hepsinde ortak olarak, tozlar önce katman üretim platformuna yayılır ve uygun bir yöntemle seçici olarak ergitilir veya bağlanır. Sürecin kalitesi, tozların üretim platformuna nasıl yayıldığı da dahil olmak üzere birçok süreç parametresine bağlıdır. Bir merdaneyle veya yayıcı ile tozların toz yatağına serilmesi işlemi olan toz yayma operasyonu, bu işlemlerde önemli bir adımdır ve yoğunluk, yüzey pürüzlülüğü gibi çeşitli süreç çıktıları üzerinde etkili olabilir. Bu çalışmada, toz yayma, katman kalınlığı, dönüş ve geçiş hızlarının parametre olarak seçildiği bir toz yayıcı silindiri ile, ayrık elemanlar yöntemi kullanılarak sayısal olarak incelenmiştir. Toz yayma parametreleri ile toz hacim paketleme oranı arasındaki ilişki, partiküllerin kendileri arasında ve partikül ile üretim plakası arasındaki etkileşimleri dikkate almak için normal ve teğetsel kuvvetleri içeren Hertz-Mindlin temas modelinin yanında yüzey enerjisinin etkilerini içeren Johnson-Kendall-Roberts (JKR) temas modeli sayısal modele eklenmiştir. Deney Tasarımı ve varyans analizi (ANOVA) ile birleştirilmiş olarak, süreç parametreleri ile yoğunluk ve dinamik yığın açısı arasındaki ilişkiyi daha geniş bir anlayış kazanmak için kullanılmıştır.

Keywords

Eklemeli imalat, ANOVA, Toz Serpme, Ayrık elemanlar metodu

Effects of Spreading Parameters on Powder Bed Quality

Abstract

Powder bed-based additive manufacturing processes such as laser powder bed fusion, binder jetting, and electron beam melting are commonly utilized in various critical areas such as medical, aviation, and energy. Common to all these operations, the powders are first spread onto the build platform in a layer-by-layer fashion and selectively fused or bound with a suitable method. The quality of the process depends on several parameters, including how the powders are spread onto the build platform. The powder spreading operation, which involves spreading powders on a powder bed with a roller or spreader, is an important step in these operations and can affect various process outputs. In this study, powder spreading is numerically investigated using the discrete element method to determine the effects of layer thickness, rotation, and translation velocities, selected as parameters with a powder spreader roller. To account for the relationship between powder spreading parameters and the powder volume packing fraction, as well as the interactions between particles themselves and between the particles and the build plate, the Hertz-Mindlin contact model, including normal tangential forces, as well as the Johnson-Kendall-Roberts (JKR) contact model, including the effects of surface energy, were added to the numerical model. A Design of Experiment combined with analysis of variance (ANOVA) was utilized to gain a broader understanding of the relationship between process parameters, green density, and dynamic angle of repose.

Keywords

Additive Manufacturing, Powder Spreading, Dicreate element Method, ANOVA

References

• Razavykia, A., Brusa, E., Delprete, C., and Yavari, R. (2020). An overview of additive manufacturing technologies-A review to technical synthesis in numerical study of selective laser melting. Materials. 13 (17), 1–22.
• Singh, R., Gupta, A., Tripathi, O., Srivastava, S., Singh, B., Awasthi, A., et al. (2019). Powder bed fusion process in additive manufacturing: An overview. Materials Today: Proceedings. 26 3058–3070.
• Dev Singh, D., Mahender, T., and Raji Reddy, A. (2021). Powder bed fusion process: A brief review. Materials Today: Proceedings. 46 350–355.
• Bai, Y., Wagner, G., and Williams, C.B. (2017). Effect of particle size distribution on powder packing and sintering in binder jetting additive manufacturing of metals. Journal of Manufacturing Science and Engineering, Transactions of the ASME. 139 (8), 1–6.
• Zhao, Y., Koizumi, Y., Aoyagi, K., Yamanaka, K., and Chiba, A. (2021). Thermal properties of powder beds in energy absorption and heat transfer during additive manufacturing with electron beam. Powder Technology. 381 44–54.
• Mostafaei, A., Elliott, A.M., Barnes, J.E., Li, F., Tan, W., Cramer, C.L., et al. (2021). Progress in Materials Science Binder jet 3D printing — Process parameters , materials , properties ,. Progress in Materials Science. 119 (June 2020), 100707.
• Onler, R., Koca, A.S., Kirim, B., and Soylemez, E. (2022). Multi-objective optimization of binder jet additive manufacturing of Co-Cr-Mo using machine learning. International Journal of Advanced Manufacturing Technology. 119 (1–2), 1091–1108.
• Gilabert, F.A., Roux, J.N., and Castellanos, A. (2007). Computer simulation of model cohesive powders: Influence of assembling procedure and contact laws on low consolidation states. Physical Review E - Statistical, Nonlinear, and Soft Matter Physics. 75 (1), 1–26.
• Maximenko, A.L., Olumor, I.D., Maidaniuk, A.P., and Olevsky, E.A. (2021). Modeling of effect of powder spreading on green body dimensional accuracy in additive manufacturing by binder jetting. Powder Technology. 385 60–68.
• Zhang, W., Mehta, A., Desai, P.S., and Fred Higgs, C. (2017). Machine learning enabled powder spreading process map for metal additive manufacturing (AM). Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017. 1235–1249.
• Miyanaji, H., Yang, L., and Momenzadeh, N. (2019). Effect of powder characteristics on parts fabricated via binder jetting process. Rapid Prototyping Journal. 25 (2),.
• Miyanaji, H., Orth, M., Akbar, J.M., and Yang, L. (2018). Process development for green part printing using binder jetting additive manufacturing. Frontiers of Mechanical Engineering. 13 (4), 504–512.
• Parteli, E.J.R. and Pöschel, T. (2016). Particle-based simulation of powder application in additive manufacturing. Powder Technology. 288 96–102.
• Mindt, H.W., Megahed, M., Lavery, N.P., Holmes, M.A., and Brown, S.G.R. (2015). Powder Bed Layer Characteristics : The Overseen First-Order Process Input. Metallurgical and Materials Transactions A.
• Haeri, S. (2017). Optimisation of blade type spreaders for powder bed preparation in Additive Manufacturing using DEM simulations. Powder Technology. 321 94–104.
• Meier, C., Weissbach, R., Weinberg, J., Wall, W.A., and Hart, A.J. (2019). Critical influences of particle size and adhesion on the powder layer uniformity in metal additive manufacturing. Journal of Materials Processing Technology. 266 (August 2018), 484–501.
• Nan, W., Pasha, M., Bonakdar, T., Lopez, A., Zafar, U., Nadimi, S., et al. (2018). Jamming during particle spreading in additive manufacturing. Powder Technology. 338 253–262.
• Fouda, Y.M. and Bayly, A.E. (2020). A DEM study of powder spreading in additive layer manufacturing. Granular Matter. 22 (1).
• Han, Q., Gu, H., and Setchi, R. (2019). Discrete element simulation of powder layer thickness in laser additive manufacturing. Powder Technology. 352 91–102.
• Phua, A., Cook, P.S., Davies, C.H.J., and Delaney, G.W. (2022). Powder spreading over realistic laser melted surfaces in metal additive manufacturing. Additive Manufacturing Letters. 3 (February), 100039.
• Lee, Y., Gurnon, A.K., Bodner, D., and Simunovic, S. (2020). Effect of Particle Spreading Dynamics on Powder Bed Quality in Metal Additive Manufacturing. Integrating Materials and Manufacturing Innovation. 9 (4), 410–422.
• Chen, H., Chen, Y., Liu, Y., Wei, Q., Shi, Y., and Yan, W. (2020). Packing quality of powder layer during counter-rolling-type powder spreading process in additive manufacturing. International Journal of Machine Tools and Manufacture. 153.
• Lampitella, V., Trofa, M., Astarita, A., and D’Avino, G. (2021). Discrete element method analysis of the spreading mechanism and its influence on powder bed characteristics in additive manufacturing. Micromachines. 12 (4), 392.
• Burman, B.C., Cundall, P.A., and Strack, O.D.L. (1980). A discrete numerical model for granular assemblies. Geotechnique. 30 (3), 331–336.
• Tsuji, Y., Tanaka, T., and Ishida, T. (1992). Lagrangian numerical simulation of plug flow of cohesionless particles in a horizontal pipe. Powder Technology. 71 (3), 239–250.
• Di Renzo, A. and Di Maio, F.P. (2004). Comparison of contact-force models for the simulation of collisions in DEM-based granular flow codes. Chemical Engineering Science. 59 (3), 525–541.
• Arratia, P.E., Duong, N. hang, Muzzio, F.J., Godbole, P., and Reynolds, S. (2006). A study of the mixing and segregation mechanisms in the Bohle Tote blender via DEM simulations. Powder Technology. 164 (1), 50–57.
• Hassanpour, A., Tan, H., Bayly, A., Gopalkrishnan, P., Ng, B., and Ghadiri, M. (2011). Analysis of particle motion in a paddle mixer using Discrete Element Method (DEM). Powder Technology. 206 (1–2), 189–194.
• Gong, H., Rafi, K., Gu, H., Janaki Ram, G.D., Starr, T., and Stucker, B. (2015). Influence of defects on mechanical properties of Ti-6Al-4V components produced by selective laser melting and electron beam melting. Materials and Design. 86 545–554.
• Zhang, J., Tan, Y., Bao, T., Xu, Y., Xiao, X., and Jiang, S. (2020). Discrete element simulation of the effect of roller-spreading parameters on powder-bed density in additive manufacturing. Materials. 13 (10).
• Körner, C., Attar, E., and Heinl, P. (2011). Mesoscopic simulation of selective beam melting processes. Journal of Materials Processing Technology. 211 (6), 978–987.
• Körner, C. and Körner, C. (2016). Additive manufacturing of metallic components by selective electron beam melting — a review 6608 (May).
• Ahmed, M., Pasha, M., Nan, W., and Ghadiri, M. (2020) A simple method for assessing powder spreadability for additive manufacturing. Powder Technology. 367 671–679.
• Chen, H., Wei, Q., Wen, S., Li, Z., and Shi, Y. (2017). Flow behavior of powder particles in layering process of selective laser melting: Numerical modeling and experimental verification based on discrete element method. International Journal of Machine Tools and Manufacture. 123 (August), 146–159.
• Chen, H., Wei, Q., Zhang, Y., Chen, F., Shi, Y., and Yan, W. (2019). Powder-spreading mechanisms in powder-bed-based additive manufacturing: Experiments and computational modeling. Acta Materialia. 179 158–171.
• Sklar, J. (2013). Minitab® Manual.
• W, Svante., S, Lars. (1989). Analysis of Variance (ANOVA). Chemometrics and Intelligent Laboratory. 6(4), 259-272.
• Vaezi, M. and Chua, C.K. (2011). Effects of layer thickness and binder saturation level parameters on 3D printing process. International Journal of Advanced Manufacturing Technology. 53 (1–4), 275–284.
• Cao, S., Qiu, Y., Wei, X.F., and Zhang, H.H. (2015). Experimental and theoretical investigation on ultra-thin powder layering in three dimensional printing (3DP) by a novel double-smoothing mechanism. Journal of Materials Processing Technology. 220 231–242.
• Wu, S., Lei, Z., Jiang, M., Liang, J., Li, B., and Chen, Y. (2022). Experimental investigation and discrete element modeling for particle-scale powder spreading dynamics in powder-bed-fusion-based additive manufacturing. Powder Technology. 117390.
• Chen, H., Cheng, T., Li, Z., Wei, Q., and Yan, W. (2022). Is high-speed powder spreading really unfavourable for the part quality of laser powder bed fusion additive manufacturing? Acta Materialia. 231 117901.