Discrete-element simulation of powder spreading process in binder jetting, and the effects of powder size

Ana Paula Clares, Guha Manogharan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

3 Scopus citations

Abstract

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.

Original languageEnglish (US)
Title of host publicationAdditive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation
PublisherAmerican Society of Mechanical Engineers
ISBN (Electronic)9780791885062
DOIs
StatePublished - 2021
EventASME 2021 16th International Manufacturing Science and Engineering Conference, MSEC 2021 - Virtual, Online
Duration: Jun 21 2021Jun 25 2021

Publication series

NameProceedings of the ASME 2021 16th International Manufacturing Science and Engineering Conference, MSEC 2021
Volume1

Conference

ConferenceASME 2021 16th International Manufacturing Science and Engineering Conference, MSEC 2021
CityVirtual, Online
Period6/21/216/25/21

All Science Journal Classification (ASJC) codes

  • Industrial and Manufacturing Engineering

Fingerprint

Dive into the research topics of 'Discrete-element simulation of powder spreading process in binder jetting, and the effects of powder size'. Together they form a unique fingerprint.

Cite this