A Computational Framework for Modeling Distortion During Sintering of Binder Jet Printed Parts

Sintering of binder jet 3D printed (BJ3DP) parts results in significant nonlinear distortion with typical shrinkage value of 5–20%, which makes design for BJ3DP and post-machining difficult. In this work, a computational modeling framework with calibration and validation procedure is developed to simulate distortion during sintering of BJ3DP parts accurately for the first time. The computational model employs the finite element analysis with a viscoplastic constitutive model that accounts for effects of gravity and friction. A calibration procedure is proposed to obtain values of different model parameters systematically through dilatometric, gravity bending, and grain growth experiments. For model validation, four bridges with different spans and a second part with a circular hole and two free overhangs are designed. The calibration procedure is applied to develop a computational model for sintered 316L stainless steel BJ3DP parts. The displacements at various locations on the sintered parts are simulated using the calibrated model and are found to have errors less than 3.5% compared to those obtained by experiment.