Preprint Article Version 1 This version is not peer-reviewed

Extrusion Process Simulation and Layer Shape Prediction during 3D-Concrete-Printing Using The Particle Finite Element Method

Version 1 : Received: 29 July 2020 / Approved: 30 July 2020 / Online: 30 July 2020 (10:46:53 CEST)

How to cite: Reinold, J.; Nerella, V.N.; Mechtcherine, V.; Meschke, G. Extrusion Process Simulation and Layer Shape Prediction during 3D-Concrete-Printing Using The Particle Finite Element Method. Preprints 2020, 2020070715 (doi: 10.20944/preprints202007.0715.v1). Reinold, J.; Nerella, V.N.; Mechtcherine, V.; Meschke, G. Extrusion Process Simulation and Layer Shape Prediction during 3D-Concrete-Printing Using The Particle Finite Element Method. Preprints 2020, 2020070715 (doi: 10.20944/preprints202007.0715.v1).

Abstract

To enable purposeful design and implementation of automated concrete technologies, precise assessment and prediction of the complex material flow at various stages of the process chain are necessary. This paper investigates the intermediate stage of the extrusion and deposition processes in extrusion-based 3D-concrete-printing, using a numerical model based on the Particle Finite Element Method (PFEM). In PFEM, due to the Lagrangian description of motion, remeshing algorithms and the alpha shape method are used to track the free surface during large deformation scenarios. The Bingham constitutive model was used for describing the rheological behaviour of fresh concrete. This model is validated by comparing the numerically predicted layer geometries with those obtained from laboratory 3D printing experiments. Extensive parametric studies were then conducted using the numerical simulation, delineating the influence of process and material parameters on the layer geometries, the dynamic surface forces generated under the extrusion nozzle and the inter-layer interactions.

Subject Areas

3D-concrete-printing; additive manufacturing; extrusion processes simulation; regularized Bingham model; fresh concrete; particle finite element method

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