Voxelization modelling based finite element simulation and process parameter optimization for Fused Filament Fabrication

In this paper, a novel approach of voxelization modelling-based Finite Element (FE) simulation and process parameter optimization for Fused Filament Fabrication (FFF) is presented. In the approach, firstly, a general meshing method based on voxelization modelling and automatic voxel element sorting is developed. Then, FE based simulation for the FFF process is conducted by combining the ANSYS Parametric Design Language (APDL) with the element birth and death technique. During the simulation, the influence of key process parameters on the temperature field, including scanning speed, molding chamber temperature and nozzle temperature, is analyzed in detail. Furthermore, an experimental platform with an adjustable molding chamber temperature for the FFF parts is established. Case studies for making Acrylonitrile Butadiene Styrene (ABS)-based parts were carried out to validate the approach. Results showed that among the process parameters, the molding chamber temperature had the most significant effect on the warping deformation of the FFF parts. The optimal parameters for the FFF process with ABS under the analyzed conditions were 50 mm/s for the scanning speed, 80 °C for the molding chamber temperature of, and 180 °C for the nozzle temperature, respectively.