Research On Equipment Design And Critical Technique Of 5-axis Fused Deposition Modeling Processs

Traditional Fused Deposition Modeling(FDM)additive manufacturing technology usually adopts a layer by layer process to fabricate 3D physical models.Fused Deposition Modeling process is one of the most common 3D printing processes because of its simple structure and low price.However,the staircase effect and the support of overhanging structure in fused deposition process have been a serious obstacle to the further expansion of the application.Based on this background,a five-axis FDM system with interference-free nozzle is designed to solve the problems.In this paper,we introduce this project from 5-axis printing system design,fundamental printing modes design,the analysis of factors influencing the surface quality,static flow beading and dynamic flow beading.Firstly this paper designs a set of five axis of 3D printing system.An adaptive posture-variable platform was designed based on the existing fused deposition modeling printing platform.In order to obtain an acceptable installation accuracy,a first-order compensation method is used measure the error of basis platform and compensate the error.And then we design an interference-free nozzle to perfect the 5-axis printing system.A control system suitable to 5-axis printing process is redesigned and a new format of Geode is redefined.To facilitate the application of five-axis printing machine,three new printing methods are proposed according to different geometries and application requirements,which include Tangential Direction Printing,Normal Sculpture Printing and Compatible Printing.The tangential direction printing mode is designed to solve the staircase effect,and the normal sculpture printing can avoid the using of support structure when printing the overhanging part.The compatible printing mode balances the efficiency and the quality by switching the 3-axis printing and 5-axis printing.These modes build up a basic system of 5-axis printing,but further development and perfection are also needed.Our work analyzes the factors which will influence the surface quality,abstracts the relationship between the inclination angle of a surface and the surface roughness.With the increase of the inclination angle,the surface roughness increases first and then decreases.This conclusion is also verified by experiments.In order to avoid the waste because of the support structure,this paper presents the concept of static flow beading and points out that there is a critical angle of beading by theoretical analysis.And experiments also proves the validity of the critical angle.At last,the concept of dynamic flow beading was presented.Considering the special movement situation during five-axis printing process,the dynamic flow beading issue is proposed.The relationship between equivalent volume and roughness is established based on elaborate experiments,which helps to figure out the boundary between safe area and beading area under different parameters of layer thickness and nozzle diameter.