About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
CFD Modeling and Simulation in Materials Processing 2027
|
| Presentation Title |
Computational Modeling of the Effects of Transient
Thermal Degradation and Fouling Layer Formation
during the Fused Filament Fabrication Process |
| Author(s) |
Ratri Chowdhury, Fatin I Hredoy, Trevor Elliott, Reetesh Ranjan |
| On-Site Speaker (Planned) |
Ratri Chowdhury |
| Abstract Scope |
Computational models of fused filament fabrication (FFF) often predict noz-
zle outlet temperatures higher than experimentally measured values. A possible source of this discrepancy is the gradual buildup of degraded polymer on the hot-end wall, which adds thermal resistance but is generally omitted from clean-wall simulations. This study combines an established melting and flow model for acrylonitrile butadiene styrene (ABS) with a time-dependent fouling model. The model evaluates the local liquid-fraction-weighted contact conductance in series with a Kern–Seaton fouling resistance, with fouling growth governed by Arrhenius kinetics based on the near-wall temperature. First, the computational setup is validated against reference results for a Dremel 3D45 hot-end at four Peclet (P e) numbers. The effects of fouling are then evaluated after 8, 24, 48, and 72 hours of cumulative printing at four feed rates. As the deposit grows, outlet temperature decreases while viscosity, feeding force, and solid penetration
depth increase. These changes are greatest at high P e because the filament has less time to absorb heat. The results indicate that hot-end fouling may account for part of the temperature overprediction observed in FFF simulations. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Polymers |