基于辊压增强的连续纤维复材3D打印方法研究
胡珍涛1，钱波12，张珂4，熊婷1，茅健12，刘钢123
1.上海工程技术大学机械与汽车工程学院，上海 201600； 2.机械工业航空大型复杂薄壁构件智能制造技术重点实验室，上海 201600；
3.上海交通大学四川研究院，成都 610213； 4.上汽大众汽车有限公司，上海 201805
Study on the Properties of 3D Printing Based on Roller Reinforced Continuous Fiber Composites
Hu Zhentao1, Qian Bo12, Zhang Ke4, Xiong Ting1, Mao Jian12, Liu Gang123
1.School of Mechanical and Automotive Engineering,Shanghai University of Engineering Science,Shanghai 201600,China; 2.Key laboratory of Intelligent Manufacturing technology of large complex thin-wall components of machinery industry aviation,Shanghai 201600,China; 3.The Sichuan Research Institute of Shanghai Jiao Tong University,Chengdu 610213,China; 4.SAIC Volkswagen Automotive CO.,Ltd,Shanghai 201805,China
摘要：目前连续纤维增强树脂的复合材料在 FDM 3D 打印技术上的应用发展迅速 ，但连续纤维材料层和树脂基础材料层两种不同材料的打印层间连接界面的孔隙率大导致打印件整体性能低。 针对连续纤维与树脂基础材料由于不同材料差异导致层间黏结差的问题 ，笔者提出通过在 3D 打印机喷头上附加辊压辅助装置对打印层面逐一进行机械压实的方法来进一步提高连续纤维增强热塑性聚合物基高性能复合材料打印件的性能。 采用正交实验法对比了试验刚性辊压轮作用于打印件成形表面时的不同辊压速度和相较于打印层面不同下压高度等参数的影响 。 为提高辊压实验的正确性，首先针对辊压速度和下压高度选定了 9 组不同参数的辊压过程进行仿真 ，通过数值模拟得出辊压装置最佳下压高度为 0.03 mm，辊压速度 4 mm/s。然后开发了相应的硬件和软件，包括双喷头与辊压装置的连接机构、辊压轨迹规划与控制算法等，最后通过实际打印模型样件测试验证了连续纤维增强复合材料 3D 打印零件通过实时辊压来提升性能方法的可行性。
Abstract：At present, continuous fiber reinforced resin composites are developing rapidly in the application of FDM 3D printing technology, but the interface porosity between the printing layers of two different materials, continuous fiber material layer and resin base material layer, leads to low overall performance of the printed parts. Aiming at the problem of poor interlayer bonding between continuous fiber and resin base materials due to the difference of different materials, a method of mechanical compaction of printing layers one by one by adding a roller assistant device to the 3D printer nozzle was explored to further enhance the performance of continuous fiber reinforced thermoplastic polymer based high-performance composite printing parts. The orthogonal experiment method was used to compare the influence of different roller speed and different press height on the printing surface. In order to improve the accuracy of the rolling experiment, the rolling process of 9 groups of different parameters aiming at the rolling speed and the rolling height was first selected for simulation. Through numerical simulation, it was concluded that the optimal rolling height and the rolling speed of the rolling device were 0.03 mm and 4 mm/s. Then the corresponding hardware and software were developed, including the connection mechanism between the dual nozzle and the roller press device, the roller press trajectory planning and control algorithm, etc. Finally, the feasibility of the continuous fiber reinforced composite 3D printing parts to enhance the performance by real-time roller press was verified by the actual printing model sample test.
关键词：连续纤维；辊压；3D打印；数值模拟；结构设计
Keywords：continuous fiber; roll pressing; 3D printing; numerical simulation; structural design
基金：国家重点研发计划项目(2018YFB1105300)
本文引用格式：
胡珍涛，钱波，张珂，等.基于辊压增强的连续纤维复材3D打印方法研究[J].工程塑料应用，2023，51(8)：92-99.
Hu Zhentao，Qian Bo，Zhang Ke，et al. Study on the properties of 3D printing based on roller reinforced continuous fiber composites[J]. Engi‐neering Plastics Application，2023，51(8)：92-99.
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