熔融沉积成型工艺中重叠率对打印制件顶面粗糙度的影响与分析

李俊美; 黄子帆; 张德海; 杨春晖

doi:10.3969/j.issn.1674-6457.2025.11.022

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (11) : 229-241. DOI: 10.3969/j.issn.1674-6457.2025.11.022

增材制造

熔融沉积成型工艺中重叠率对打印制件顶面粗糙度的影响与分析

李俊美^1,2, 黄子帆^1,2, 张德海^3,*, 杨春晖⁴

作者信息 +

Effect and Analysis of Overlap Rate on Top Surface Roughness of Printed Parts in Melt Deposition Molding Process

LI Junmei^1,2, HUANG Zifan^1,2, ZHANG Dehai^3,*, YANG Chunhui⁴

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文章历史 +

摘要

目的揭示熔融沉积成型打印制件顶面波纹效应的形成机制,并建立打印制件顶面粗糙度的预测理论模型,来指导工艺参数的优化,最终实现顶面质量的精准控制。方法首先研究打印制件顶面周期性波纹效应的产生机制,并以此建立了重叠率与顶面粗糙度的几何模型。其次,通过实验验证了不同层高和重叠率下顶面粗糙度模型的准确性,并对误差来源进行了分析。最后,在模型的基础上,阐明了层高、进料长度和打印速率等工艺参数与顶面粗糙度之间的内在联系。结果在重叠率从0%增至临界重叠率的过程中,顶面粗糙度逐渐降低,这是因为在此过程中,重叠面积逐渐能够完全填充气隙面积。层高不仅通过改变重叠率直接影响顶面质量,还会造成气隙面积与重叠面积的相对变化速率有所差异,这双重作用是导致层高对顶面粗糙度的影响呈现显著非线性特征的主要因素。结论挤压长丝的边缘效应是顶面粗糙度产生的根源,而重叠率是影响顶面粗糙度的关键参数。这一结论为优化打印制件的顶面粗糙度奠定了理论基础。

Abstract

The work aims to reveal the formation mechanism of the top surface ripple effect in fused deposition modeling (FDM) printed parts and establish a theoretical model for predicting top surface roughness, so as to guide process parameter optimization and ultimately achieve precise control of top surface quality. Firstly, the generation mechanism of the periodic waviness effect on the top surface of printed parts was investigated, and a geometric model related to the relationship between overlap rate and top surface roughness was established. The accuracy of the top surface roughness model was then experimentally verified for different layer heights and overlap rates, and the sources of error were analyzed. Finally, based on the model, the intrinsic relationship between process parameters such as layer height, feed length, and printing rate and top surface roughness was elucidated. As the overlap rate increased from zero to the critical overlap rate, the top surface roughness gradually decreased. This was because the overlap area gradually filled the air gap area. Layer height not only directly affected top surface quality by changing the overlap rate but also caused a difference in the relative rate of change between the air gap area and the overlap area. This dual effect was the primary factor that led to the significant nonlinear characteristics of the effect of layer height on top surface roughness. The edge effect of extruded filaments is the root cause of top surface roughness, and the overlap rate is the key parameter affecting top surface roughness. This conclusion lays a theoretical foundation for optimizing the top surface roughness of printed parts.

导出引用

李俊美, 黄子帆, 张德海, 杨春晖. 熔融沉积成型工艺中重叠率对打印制件顶面粗糙度的影响与分析[J]. 精密成形工程. 2025, 17(11): 229-241 https://doi.org/10.3969/j.issn.1674-6457.2025.11.022

LI Junmei, HUANG Zifan, ZHANG Dehai, YANG Chunhui. Effect and Analysis of Overlap Rate on Top Surface Roughness of Printed Parts in Melt Deposition Molding Process[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 229-241 https://doi.org/10.3969/j.issn.1674-6457.2025.11.022

中图分类号： TP391.73

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