Numerical Simulation and Experimentation of Additive Manufacturing Processes with Polyurethane Foams

Abstract

AbstractFoam Additive Manufacturing (FAM) is the additive manufacturing process allowing parts to be obtained by depositing layers of polyurethane foam using a high-pressure machine. This inexpensive technology allows large parts to be produced in a reduced time. However, the quality of the parts produced by the FAM technique is greatly affected by the various thermal phenomena present during manufacturing and by the geometrical deviations of the layers due to the expansion of the PU foam. Numerical simulation remains an effective analytical tool for studying these phenomena. The aim of this work is to build a geometric and thermal model predictive of the FAM process by the finite element method, the final objective of which is to provide temperature maps throughout the manufacturing process and also to choose the best 3D printing strategy to have a model with constant cords and the smallest possible form deviation. The proposed model and the various simulation techniques used are detailed in this article. This model is developed under the finite element code Rem3D, and validated by experimental tests carried out on a FAM machinery or a robot, an example of which is detailed in this article.