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Prior literature employed a finite element based fully coupled algorithm that solved the flow/orientation coupling effects in extrusion deposition additive manufacturing, i.e., a key component for identifying the material properties of solidified deposited polymer composites. However, the complex iterative solution protocol reduces the computational capability of the algorithm. This paper simplifies the finite element based fully coupled algorithm by employing a scalar representation of the fourth order orientation tensor affected viscosity tensor. The revised code predicts similar fiber orientation results as compared to a related prior study. With the simplified fully coupled algorithm, effects of material deposition rate and fiber aspect ratio on a 2D planar large area extrusion deposition flow are explored, where the power law rheology model is employed for the flow simulation. Computed results show that an increased material deposition rate reduces the extrudate-swell ratio of the melt front and varies the local fiber orientation of the deposited bead especially near the flow region in contact with the substrate. Higher fiber aspect ratio enhances the principal fiber alignment of the extrusion and deposition flows, where the maximum local difference of the principal  A   11  component is 23% with increasing fiber aspect ratio from 10 to 25.

international polymer processing

Exploring the applicability of a simplified fully coupled flow/orientation algorithm developed for polymer composites extrusion deposition additive manufacturing