TY - GEN
T1 - Discrete-element simulation of powder spreading process in binder jetting, and the effects of powder size
AU - Clares, Ana Paula
AU - Manogharan, Guha
N1 - Funding Information:
The author acknowledges the support from 2020 PA Manufacturing Fellows Initiative Grant, NSF CMMI award# #1944120, Flow Science, The Pennsylvania State University, and ExOne. Special thanks to Tess Zangrilli from Flow Science for her support.
Publisher Copyright:
Copyright © 2021 by ASME
PY - 2021
Y1 - 2021
N2 - Binder Jetting has gained particular interest amongst Additive Manufacturing (AM) techniques because of its wide range of applications, broader feasible material systems, and absence of rapid melting-solidification issues present in other AM processes. Understanding and optimizing printing parameters during the powder spreading process is essential to improve the quality of the final part. In this study, a Discrete Element Method (DEM) simulation is employed to evaluate the powder packing density, flowability, and porosity during powder spreading process utilizing three different powder groups. Two groups are formed with monoidal size distributions (75-84 µm and 100-109 µm), and the third one consisting of a bimodal distribution (50 µm +100 µm). A thorough investigation into the effects of powder size distribution during the powder spreading step in a binder jetting process is conducted using ceramic foundry sand. It was observed that coarser particles result in higher flowability (62% decrease in repose angle) than finer ones due to the cohesion effect present in the latter. A bimodal size distribution yields the highest packing density (8% increase) and lowest porosity (~12% reduction) in the powder bed, as the finer particles fill in the voids created between the coarser ones. Findings from this study are directly applicable to binder-jetting AM process, and also offer new insights for AM powder manufacturers.
AB - Binder Jetting has gained particular interest amongst Additive Manufacturing (AM) techniques because of its wide range of applications, broader feasible material systems, and absence of rapid melting-solidification issues present in other AM processes. Understanding and optimizing printing parameters during the powder spreading process is essential to improve the quality of the final part. In this study, a Discrete Element Method (DEM) simulation is employed to evaluate the powder packing density, flowability, and porosity during powder spreading process utilizing three different powder groups. Two groups are formed with monoidal size distributions (75-84 µm and 100-109 µm), and the third one consisting of a bimodal distribution (50 µm +100 µm). A thorough investigation into the effects of powder size distribution during the powder spreading step in a binder jetting process is conducted using ceramic foundry sand. It was observed that coarser particles result in higher flowability (62% decrease in repose angle) than finer ones due to the cohesion effect present in the latter. A bimodal size distribution yields the highest packing density (8% increase) and lowest porosity (~12% reduction) in the powder bed, as the finer particles fill in the voids created between the coarser ones. Findings from this study are directly applicable to binder-jetting AM process, and also offer new insights for AM powder manufacturers.
UR - http://www.scopus.com/inward/record.url?scp=85112412713&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=85112412713&partnerID=8YFLogxK
U2 - 10.1115/MSEC2021-63351
DO - 10.1115/MSEC2021-63351
M3 - Conference contribution
AN - SCOPUS:85112412713
T3 - Proceedings of the ASME 2021 16th International Manufacturing Science and Engineering Conference, MSEC 2021
BT - Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation
PB - American Society of Mechanical Engineers
T2 - ASME 2021 16th International Manufacturing Science and Engineering Conference, MSEC 2021
Y2 - 21 June 2021 through 25 June 2021
ER -