(519d) Numerical Simulation of the Extrusion Process in Fused Deposition Modeling: The Effects of Process Variables on the Pressure Drop in the Nozzle

Fused deposition modeling (FDM) has been used and developed as one of the most popular techniques in additive manufacturing. One of the important aspects to be considered in process conditions of FDM is energy requirement to push filaments into the nozzle, which is directly related to pressure drop. In this work, we performed CFD simulation of the extrusion process in FDM using OpenFOAM, an open source simulation tool based on the finite volume method. A computational module for solving the equations of non-isothermal multiphase flows, which we developed, is used to systematically investigate the effects of process variables, such as, nozzle temperature, substrate velocity, feed stock thermal conductivity, gap distance, feed velocity inside the nozzle, and the nozzle geometry, on the pressure drop inside the nozzle. The simulation results are then compared with analytical and experimental results available in the literature.