CN115256924A - Fiber composite material 3D printing method with controllable fiber distribution - Google Patents

Fiber composite material 3D printing method with controllable fiber distribution Download PDF

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Publication number
CN115256924A
CN115256924A CN202210816496.4A CN202210816496A CN115256924A CN 115256924 A CN115256924 A CN 115256924A CN 202210816496 A CN202210816496 A CN 202210816496A CN 115256924 A CN115256924 A CN 115256924A
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CN
China
Prior art keywords
nozzle
fiber
filament
beam splitting
wall surface
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Pending
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CN202210816496.4A
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Chinese (zh)
Inventor
权震震
刘程
张弘楠
覃小红
俞建勇
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Donghua University
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Donghua University
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Priority to CN202210816496.4A priority Critical patent/CN115256924A/en
Publication of CN115256924A publication Critical patent/CN115256924A/en
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/209—Heads; Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/321—Feeding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

The invention relates to a fiber composite material 3D printing method with controllable fiber distribution. The method comprises the following steps: arranging a beam splitting filament in the through hole nozzle, wherein the beam splitting filament is positioned in the vertical outlet section or the contraction outlet section, and two ends of the beam splitting filament are respectively arranged on the inner wall surface of the nozzle outlet or the contraction inner wall surface to obtain a beam splitting nozzle; adjusting the position of the beam splitting nozzle to ensure that the beam splitting silk forms a certain angle with the transverse direction or the longitudinal direction of the printing plane at the zero printing moment; feeding resin materials and fiber bundles into a beam splitting nozzle, respectively introducing the fiber bundles into different subareas, and feeding resin filaments through a gear to perform 3D printing. The method designs the distribution of the fiber bundles in the deposited filament by controlling the quantity and the types of the fiber bundles introduced into different regions and the transverse angle of the split filament relative to a printing plane, thereby realizing the 3D printing of the low-porosity composite material with controllable fiber distribution.

Description

Fiber composite material 3D printing method with controllable fiber distribution
Technical Field
The invention belongs to the technical field of 3D printing, and particularly relates to a fiber composite material 3D printing method with controllable fiber distribution.
Background
The continuous fiber reinforced composite material is a popular composite material which is light in weight but can be comparable to the traditional metal and alloy materials in the performances such as strength, rigidity and the like, and has more successful application achievements in the fields of aerospace, automobiles, traffic, industrial devices, sports and the like. The advantages of low cost, personalized manufacturing and the like of the Fused Filament Fabrication (FFF) 3D printing technology further facilitate the application of fiber reinforced composites in a wider range of scenes.
Compared with 3D printing of the preimpregnated continuous fiber reinforced composite material, the 3D printing of the in-situ composite impregnated continuous fiber reinforced composite material omits the step of using preimpregnation equipment to preimpregnate fiber bundles, and has the huge advantages of low cost and instant and controllable fiber content. The disadvantages of the current commercial single orifice nozzles are also apparent: firstly, the resin in the nozzle is usually higher in viscosity, the pressure of a melt on a fiber bundle from a wire inlet to a nozzle outlet is continuously reduced, the molten resin is difficult to completely impregnate the small-volume fiber bundle, and when the content of the fiber is increased, the aggregation among the fibers is more unfavorable for the impregnation of the resin on the fiber bundle, so that more pores exist in the composite material, and the properties of the material can be obviously reduced by the pores; secondly, when different types of fiber bundles are used for hybrid printing to realize the differentiation performance, the different types of fiber bundles can be entangled with each other disorderly, and the controllable design of the differentiation performance of the material is difficult to realize.
Disclosure of Invention
The invention aims to solve the technical problem of providing a fiber composite material 3D printing method with controllable fiber distribution.
The invention provides a fiber composite material 3D printing method with controllable fiber distribution, which comprises the following steps:
(1) Arranging a beam splitting filament in the through hole nozzle, wherein the beam splitting filament is positioned in the vertical outlet section or the contraction outlet section, and two ends of the beam splitting filament are respectively arranged on the inner wall surface of the nozzle outlet or the contraction inner wall surface to obtain a beam splitting nozzle;
(2) Adjusting the position of the beam splitting nozzle in the step (1) according to the fiber bundle distribution required by the material and a preset printing path, so that a certain angle is formed between the beam splitting filament and the transverse direction or the longitudinal direction of a printing plane at the zero printing time;
(3) And (3) feeding the resin material and the fiber bundles into the beam-splitting nozzle in the step (2), respectively introducing the fiber bundles into different subareas, feeding the resin filaments through a gear, and performing 3D printing to obtain the composite filament of the fiber reinforced resin.
Preferably, the bundled fibers in the step (1) are rigid or flexible, when the bundled fibers are rigid, the outer ends of the bundled fibers can be welded on the inner wall surface or the contracted inner wall surface of the nozzle outlet, or clamped on a smooth concave track etched on the inner wall surface or the contracted inner wall surface of the nozzle outlet, and for the latter, the bundled fibers 7 can automatically adjust the positions due to the fiber tension when the printing path changes; when the beam splitting wire is flexible, the beam splitting wire can penetrate into the hole on the inner wall surface of the outlet of the nozzle to be fixed.
Preferably, the bundling wire in the step (1) is made of a metal material or a nonmetal material, the metal material is a steel wire or an iron wire, and the nonmetal material is aramid fiber. The bundling wires need to have good heat resistance, smooth surface, uniform thickness and certain strength, and the finer the fineness, the better.
Preferably, in step (1), there are 1 or several split filaments, and the outer ends of the split filaments may be located on the same or different planes in the vertical direction.
Preferably, the through-hole nozzle in the step (1) comprises external threads, a nozzle outer wall surface, a vertical inner wall surface, a contracted inner wall surface and an outlet inner wall surface; the beam splitting wire is positioned in the nozzle and divides the outlet of the nozzle into zones.
Preferably, the transverse angle of the tow filament to the print plane in step (2) is 0 °, 30 °, 45 ° or 60 °.
Preferably, the fiber bundles in the step (3) use low filament number continuous fibers with the same or different varieties and the same or different filament numbers.
Preferably, the resin material in the step (3) is polylactic acid, nylon, ABS, polycarbonate or PEEK.
Preferably, the fiber bundle in the step (3) comprises one or more of glass fiber, carbon fiber and aramid fiber.
The process principle of the Fused Filament Fabrication (FFF) 3D printing technique is: under the action of wire feeding gear, consumable material with certain diameter (such as 1.75mm or 2.85 mm) is fed into high-temperature printing spray head at certain speed, heated and melted therein, and under the action of extrusion force of continuously fed wire, the melted resin is extruded out through nozzle with certain aperture (such as 0.4mm, 0.5mm, 0.8mm, 1.0mm, 1.5mm, etc.), and deposited on deposition bed with lower temperature to be cooled and solidified. The sprayer advances according to a certain path while extruding the resin, and when the deposition of one layer is finished, the sprayer can be lifted by one layer height to deposit the next layer, and the three-dimensional entity is obtained by stacking the layers.
Advantageous effects
In the prior art, a conventional single-hole nozzle is used for carrying out in-situ composite impregnation 3D printing on a continuous fiber composite material, and the problems that a high-volume-content fiber bundle and resin are not completely impregnated, and fiber distribution is disordered and uncontrollable in the printing process of a high-single-filament-number fiber bundle or a hybrid fiber bundle exist. The existence of the tow yarn can enlarge the contact area between the resin and the fiber tow, the fiber is thinner after being split, and the resin is easier to be impregnated into the fiber tow in limited time and travel length, thereby improving the composite condition of the resin and the fiber tow.
Drawings
FIG. 1 is a cross-sectional view of a conventional single orifice nozzle (exemplified by a circular orifice nozzle).
FIG. 2 is a cross-sectional view of a beam splitting nozzle of the present invention (based on a circular orifice nozzle).
Fig. 3 is a bottom view of a 3D print nozzle of the present invention (based on a circular orifice nozzle, as exemplified by a dual zone nozzle).
Fig. 4 is a bottom view of a 3D print nozzle of the present invention (based on a circular hole nozzle, taking a three-zone nozzle as an example).
Fig. 5 is a bottom view of a 3D print nozzle of the present invention (based on a circular orifice nozzle, taking a four-zone nozzle as an example).
Fig. 6 is a bottom view of a 3D print nozzle of the present invention (based on a circular orifice nozzle, taking a five-zone nozzle as an example).
Fig. 7 is a bottom view of a 3D print nozzle of the present invention (based on a circular orifice nozzle, taking a six-zone nozzle as an example).
In the figure: 1 is external thread, 2 is nozzle outer wall face, 3 is vertical inner wall face, 4 is shrink inner wall face, 5 is export inner wall face, 6 is nozzle export edge, 7 is the bundling silk.
Detailed Description
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention can be made by those skilled in the art after reading the teaching of the present invention, and these equivalents also fall within the scope of the claims appended to the present application.
Example 1
A fiber composite material 3D printing method with controllable fiber distribution comprises the following steps:
(1) Arranging a thin steel wire beam splitting wire in the through hole nozzle, wherein the beam splitting wire is positioned in the vertical outlet section, and two ends of the beam splitting wire are respectively welded on the same height of the inner wall surface of the nozzle outlet to obtain a beam splitting nozzle;
(2) Presetting a printing path as a concentric printing path on each layer, and adjusting the position of a nozzle to ensure that the beam splitting silk and the transverse direction of a printing plane form an angle of 0 degree at the zero printing moment;
(3) The method comprises the steps that a fiber bundle A (200D Kevlar aramid fiber) and a fiber bundle B (1K carbon fiber) are respectively introduced into two zones, ABS resin filaments are fed through a gear, when a printing head moves transversely, the fiber bundle A and the fiber bundle B are distributed on two sides of a transverse printing path, when the printing head moves longitudinally, the two zones can enable the two fiber bundles to be distributed in a stacked mode relative to the front and back positions of the printing head, and molten resin can be impregnated into the fiber bundle A and the fiber bundle B and between the two fiber bundles due to the separation effect of a bundling wire and the permeation effect of the molten resin, so that the low-porosity composite material with the fiber bundle A and the fiber bundle B distributed transversely and bilaterally and longitudinally in a stacked mode is obtained through printing.
Wherein the beam-splitting nozzle in the step (1) comprises a conventional circular through-hole nozzle, and the inner flow passage comprises a vertical section, a contraction section and an outlet section. The two ends of the thin steel wire bundle filaments are embedded into the inner wall surface of the outlet, so that the outlet of the nozzle is divided into two zones along the plane symmetry axis of the outlet end of the nozzle, and two fiber bundles can be extruded out of the two zones respectively.
Example 2
The split yarns are arranged in the high-temperature nozzle, so that the split yarns have good heat resistance, need to have certain strength due to the fact that the split yarns need to bear the tension of fibers and the pressure of resin, need to have smooth surfaces and uniform thickness so as to reduce the damage to the fibers and the interference to the extruded resin as much as possible, can be made of aramid fibers, and the rest of the split yarns are the same as those in the embodiment 1, so that the composite material is obtained.
Example 3
And (2) etching a smooth concave track on the wall surface of the inner wall surface of the outlet in the step (1), and clamping the outer end of the rigid beam splitting wire in the smooth concave track, so that the beam splitting wire can automatically rotate to a position parallel to the printing path due to the tension of the fiber when the printing path changes, two beams of fiber can be always deposited on two sides of the printing path for the beam splitting double-zone nozzle, and the rest is the same as that in the embodiment 1, so that the composite material is obtained.
Example 4
The split filaments may be two or more (as shown in fig. 3-5), in order to reduce the influence on the resin extrusion as much as possible, the outer ends of the split filaments with different orientations may be respectively distributed on different planes in the vertical direction, so that the zoning effect can be achieved, and the rest are the same as in embodiment 1, so as to obtain the composite material.

Claims (9)

1. A fiber composite material 3D printing method with controllable fiber distribution comprises the following steps:
(1) Arranging a beam splitting filament in the through hole nozzle, wherein the beam splitting filament is positioned in the vertical outlet section or the contraction outlet section, and two ends of the beam splitting filament are respectively arranged on the inner wall surface of the nozzle outlet or the contraction inner wall surface to obtain a beam splitting nozzle;
(2) Adjusting the position of the beam splitting nozzle in the step (1) according to the fiber bundle distribution required by the material and a preset printing path, so that a certain angle is formed between the beam splitting filament and the transverse direction or the longitudinal direction of a printing plane at the zero printing time;
(3) And (3) feeding the resin material and the fiber bundles into the beam-splitting nozzle in the step (2), respectively introducing the fiber bundles into different subareas, feeding the resin filaments through a gear, and performing 3D printing to obtain the composite filament of the fiber reinforced resin.
2. The method according to claim 1, wherein the bundle filament in step (1) is rigid or flexible, and when the bundle filament is rigid, the outer end of the bundle filament can be welded on the inner wall surface or the inner contracted wall surface of the nozzle outlet, or clamped on a smooth concave track etched on the inner wall surface or the inner contracted wall surface of the nozzle outlet; when the bundling wire is flexible, the bundling wire can penetrate into the hole on the inner wall surface of the outlet for fixing.
3. The method according to claim 1, wherein the bundling wire in the step (1) is made of a metal material or a nonmetal material, the metal material is made of steel wires or iron wires, and the nonmetal material is made of aramid fibers.
4. The method according to claim 1, wherein the bundle filaments in step (1) have 1 or several bundle filaments, and the outer ends of the bundle filaments may be located on the same or different planes in the vertical direction.
5. The method of claim 1, wherein the through-hole nozzle of step (1) comprises external threads, a nozzle outer wall surface, a vertical inner wall surface, a converging inner wall surface, and an outlet inner wall surface; the beam splitting wire is positioned in the nozzle and divides the outlet of the nozzle into zones.
6. The method of claim 1, wherein in step (2) the tow filament is at an angle of 0 °, 30 °, 45 ° or 60 ° to the transverse direction of the printing plane.
7. The method according to claim 1, wherein the low filament count continuous fiber bundles of the same or different types and the same or different filament counts are used as the fiber bundles in the step (3).
8. The method according to claim 1, wherein the resin material in the step (3) is polylactic acid, nylon, ABS, polycarbonate or PEEK.
9. The method according to claim 1, wherein the fiber bundle in the step (3) comprises one or more of glass fiber, carbon fiber and aramid fiber.
CN202210816496.4A 2022-07-12 2022-07-12 Fiber composite material 3D printing method with controllable fiber distribution Pending CN115256924A (en)

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Application Number Priority Date Filing Date Title
CN202210816496.4A CN115256924A (en) 2022-07-12 2022-07-12 Fiber composite material 3D printing method with controllable fiber distribution

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116638751A (en) * 2023-05-20 2023-08-25 南京航空航天大学 Printing method based on high-temperature and low-temperature dual-material spatial distribution

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116638751A (en) * 2023-05-20 2023-08-25 南京航空航天大学 Printing method based on high-temperature and low-temperature dual-material spatial distribution
CN116638751B (en) * 2023-05-20 2024-03-01 南京航空航天大学 Printing method based on high-temperature and low-temperature dual-material spatial distribution

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