Simplified Model Predicts Binder Behavior in Sand Mold Printing

Binder jetting is a crucial process in additive manufacturing (AM) and is widely used in sand mold casting. This study explores the challenges of simulating binder droplets in ANSYS Fluent, including complexity and computational time. To overcome these challenges, we propose a geometric approach tha...

Full description

Saved in:
Bibliographic Details
Published inApplied sciences Vol. 13; no. 12; p. 6985
Main Authors Li, Yen-Ting, Cheng, Yih-Lin, Tang, Kea-Tiong
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.06.2023
Subjects
3-D printers
3D printing
Additive manufacturing
Analysis
ANSYS Fluent
binder jetting
Boundary conditions
circular shape
Computer applications
Computing time
Contact angle
Droplets
dynamic mesh
Finite volume method
Fluid dynamics
Gases
geometric approach
Manufacturing
Optimization
Particle size
Penetration depth
Porosity
Porous materials
Porous media
Reynolds number
Sand
Sand & gravel
Sand casting
Sand molds
Simulation
Viscosity
Online AccessGet full text

Cover

More Information
Summary:Binder jetting is a crucial process in additive manufacturing (AM) and is widely used in sand mold casting. This study explores the challenges of simulating binder droplets in ANSYS Fluent, including complexity and computational time. To overcome these challenges, we propose a geometric approach that models the binder droplet as a circular shape instead of an actual droplet. Additionally, the dynamic mesh feature is employed to transform the initial boundary condition into a wall condition at a specified time interval (Δt). This simplified approach eliminates the need to simulate actual droplets, leading to significant computational resource and time savings. By adopting this geometric approach, we can accurately predict the diffusion and penetration behavior of binder droplets with varying materials and volumes in porous media with different porosities. Through data analysis, it was found that the main variables affecting the diffusion diameter and penetration depth are binder volume and porosity. The successful implementation of this simplified model enables researchers and engineers to expedite the simulation of binder behavior, facilitating process optimization and enhancing the understanding of binder jetting technology in the field of additive manufacturing.
ISSN:2076-3417
2076-3417
DOI:10.3390/app13126985