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Effect of blade geometry on the powder spreading process in additive manufacturing

Particuology 2024年第11期94卷 345-355页

作者： Deze Yang Xihua Chu Qipeng Liu School of Civil Engineering Wuhan UniversityWuhan430072China Jiangxi Key Laboratory of Forming and Joining Technology for Aerospace Components Nanchang Hangkong UniversityNanchang330063China

In powder-bed-based additive manufacturing,the quality of the powder bed is closely related to the geometry of the blade used during the powder spreading *** this study,the spreading process with the vertical blade,inclined blade,and round blade with different radii was performed by discrete element method to investigate the effects of blade geometry on powder *** results show that at the same spreading parameters,the round blade caused the highest density than inclined blade and vertical *** the round blade radius can improve the packing density of the powder bed,but it has little effect on the *** increase in packing density is related to the transitional smoothness of the blade surface at the entrance of the powder *** smoother the shape transition of the blade surface at the powder bed entrance,the powders enter the powder bed more gently,so more powders enter the powder bed,resulting in higher packing *** results may provide suggestions for improving the laser melting process.

关键词： Additive manufacturing powder spreading Blade geometry Discrete element method

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Discrete element method model calibration and validation for the spreading step of the powder bed fusion process to predict the quality of the layer surface

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Particuology 2024年第11期94卷 261-273页

作者： Marco Lupo Sina Zinatlou Ajabshir Daniele Sofia Diego Barletta Massimo Poletto Department of Industrial Engineering University of SalernoVia Giovanni Paolo II13284084FiscianoSAItaly Granutools Rue Jean Lambert Defrene 1074340 AwansBelgium Dipartimento di Ingegneria Informatica ModellisticaElettronica e Sistemistica dell’Universita’della CalabriaVia Pietro Bucci87036 Rende CS(CS)Italy

A Discrete Element Method model,including interparticle cohesive forces,was calibrated and validated to develop a tool to predict the powder layer’s quality in the powder bed fusion *** elastic contact model was used to describe cohesive interparticle *** surface energy of the model particles was estimated by assuming that the pull-off force should provide the strength of the material evaluated at low consolidation with shear test *** particle rolling friction was calibrated considering the bulk density of the layer produced by the spreading *** model was validated with the experiments by comparing the wavelet power spectra obtained with the simulations with those of the experimental layers illuminated by grazing *** calibration proposed in this study demonstrated superior performance compared to our previous methods,which relied on measuring the angle of repose and unconfined yield strength.

关键词： Additive manufacturing powder bed fusion Laser sintering powder spreading Discrete element method Wavelet transform

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Comparison of roller-spreading and blade-spreading processes in powder-bed additive manufacturing by DEM simulations

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Particuology 2022年第7期20卷 48-58页

作者： Jiangtao Zhang Yuanqiang Tan Xiangwu Xiao Shengqiang Jiang Institute of Manufacturing Engineering Huaqiao UniversityXiamen 361021China National&Local Joint Engineering Research Center for Intelligent Manufacturing Technology of Brittle Material Products Huaqiao UniversityXiamen 361021China School of Mechanical Engineering Xiangtan UniversityXiangtan 411105China

The roller-spreading and blade-spreading are main powder spreading methods in powder-bed additive *** discrete element method was introduced to simulate nylon powder spreading by both roller and blade *** two spreading processes were compared from several aspects including particle flow behavior,particle contact forces,forces exerted on spreaders,particle segregation and powder layer *** is found that powder spreading methods mainly affect the movement trajectory of particles,particle contact forces and forces exerted on *** dispersion and circulation movement of particles occur inside the powder pile by roller-spreading,while particles have relatively weak dispersion by the *** normal force applied to the roller introduces a compacting effect on the powder pile and creates strong force chains that distribute uniformly in the powder ***,the powder bed with higher density can be obtained by roller-spreading in thicker powder layer due to the compacting *** blade spreader sustains tangential force mainly,so the blade-spreading process limits its application to thicker powder *** the powder layer thickness increases,the roller-spreading is more sensitive to segregation index than that of the *** comprehensive comparison of two spreading processes provides criteria for selecting spreading methods.

关键词： Additive manufacturing powder spreading Roller Blade Discrete element metho

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Spreadability of powders for additive manufacturing:A critical review of metrics and characterisation methods

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Particuology 2024年第10期93卷 211-234页

作者： Fatemeh A.Talebi Zobaideh Haydari Hamid Salehi Mozhdeh Mehrabi Jabbar Gardy Mike Bradley Andrew E.Bayly Ali Hassanpour School of Chemical and Process Engineering University of LeedsLeedsLS29JTUK School of Engineering University of GreenwichGreenwichME44TBUK Cormica Limited Listerhills Science ParkCampus RoadBradfordBD71HRUK

powder bed fusion methods of additive manufacturing (AM) require consistent, reproducible, and uniform layers of powder for the reliable production of high-quality parts, where properties of powder are central to achieving this. Among these properties, powder flowability and spreadability play critical roles in determining the quality of these powder *** extensive research has been conducted on powder flow and spreading behaviour, and on their characterisation, there is little critical comparison and review of these terms in the context of AM. Such a review is necessary to further develop and enhance our comprehension of spreading dynamics and its relation to powder properties in AM *** review paper aims to build a coherent understanding of the correlation between powder characteristics and spreading in powder based additive manufacturing and its impact on manufactured parts. It highlights the current progress in comprehending spreading dynamics, the influence of powder characteristics, environmental conditions, spreading system, and the development of testing tools to assess powder spreadability. Furthermore, the paper critically discusses the challenge of finding appropriate quantitative metrics and recent advances in the use of standardised methods for evaluating powder spreadability.

关键词： powder spreading powder flowability powder properties Quality of layer and final products

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