Prediction of Distortion and Residual Stress Evolution in the Fused Filament Fabrication Process Using Higher-Order Finite Elements

Abstract

This work presents a higher-order finite element-based process modeling framework for material extrusion additive manufacturing. The numerical modeling is based on higher-order structural theories derived via the Carrera Unified Formulation, and allows for high-fidelity modeling in a computationally efficient manner. The element activation strategy is employed to simulate the material deposition process. A thermo-mechanical analysis is performed to determine the evolving temperature field within the part during the printing process, which is subsequently used to evaluate the distortion of the printed structure. Numerical assessments are performed, and the agreement of the numerical predictions with available reference experimental data validates the proposed process modeling framework for additive manufacturing.