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A DEM study of powder spreading in additive layer manufacturing

机译：添加剂层制造中粉末铺展的DEM研究

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摘要

In this paper, discrete element method simulations were used to study the spreading of an idealised, blade based, powder coating system representative of the spreading of spherical, mono-sized, non-cohesive titanium alloy (Ti6AlV4) particles in additive layer manufacturing applications. A vertical spreader blade was used to accelerate a powder heap across a horizontal surface, with a thin gap between the blade and the surface, resulting in the deposition of a thin powder layer. The results showed that it is inevitable to deposit a powder layer with a lower packing fraction than the initial powder heap due to three mechanisms: shear-induced dilation during the initiation of powder motion by the spreader; dilation and rearrangement due to powder motion through the gap; and the inertia of the particles in the deposited powder layer. It was shown that the process conditions control the contribution of these three mechanisms, and that the velocity profile in the shear layer in front of the gap is critical to the final deposited layer packing fraction. The higher the mean normalised velocity in the shear layer the lower the deposited layer packing fraction. The gap thickness and the spreader blade velocity affect the properties of the deposited layer; with the former increasing its packing fraction and the latter decreasing it. The analysis presented in this study could be adapted to powders of different materials, morphologies and surface properties.
机译：在本文中，离散元素方法模拟用于研究理想的，基于叶片的粉末涂料系统的扩散，该系统代表添加剂层制造应用中球形，单一尺寸，非粘性的钛合金（Ti6AlV4）粒子的扩散。使用垂直的散布刮刀来加速粉末堆积在水平表面上，并且在刮刀和表面之间留有很薄的间隙，从而导致粉末薄层的沉积。结果表明，由于以下三种机理，不可避免地要沉积出堆积率比初始粉末堆低的粉末层：三是在撒布机启动粉末运动过程中，由剪切引起的膨胀；第二是由散布器产生的粉末。粉末通过间隙运动引起的膨胀和重排；和沉积粉末层中颗粒的惯性。结果表明，工艺条件控制着这三个机理的作用，并且在间隙前的剪切层中的速度分布对最终沉积层的填充率至关重要。剪切层中的平均归一化速度越高，沉积层的填充率越低。间隙厚度和扩展叶片速度会影响沉积层的性能。前者增加了包装率，后者减少了包装率。这项研究中提出的分析可适用于不同材料，形态和表面性质的粉末。

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