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Additive manufacturing of the high-performance thermoplastics: Experimental study and numerical simulation of the Fused Filament Fabrication

Abstract : Additive manufacturing (AM) refers to a wide variety of manufacturing processes for rapid prototyping and production of final and semi-final products. In opposite to conventional or subtractive processes, in additive manufacturing, the material is gradually added layer by layer to form the parts. AM enables the fabrication of complex parts which were impossible or not cost-effective to manufacture with the traditional processes. Fused Filament Fabrication (FFF) is based on the melting of a polymeric filament in an extruder; the filament is then deposited layer by layer to manufacture the final parts. Despite growing interest from industries and a large audience in recent years, these manufacturing processes are still not well mastered, especially for not mass-produced polymers. In this thesis, we will take an insight into the printability of PEEK (Polyetheretherketone). The aim is to find the printing conditions to obtain the best quality of the printed parts by FFF process. In the first step, we have determined the polymer properties influencing the quality of the printed parts by FFF. The rheological properties, the surface tension, the thermal conductivity and thermal expansion have been determined experimentally. Then, the coalescence phenomenon of the polymeric filaments has been studied by experimental, analytical and numerical simulation. Furthermore, the stability of the filament and its flow properties when it exits from the extruder in the FFF process has been determined by experimental, analytical and numerical simulation. Then, we have focused on the determination of the die swelling of PEEK extrudate. Lastly, the kinetics of isothermal and non-isothermal crystallization of PEEK has been studied by experimental study. The kinetics of crystallization has been applied to FFF process by numerical simulation in order to determine the optimum environment temperature to control the crystallization of printed parts. The crystallization of PEEK reaches its maximum value (about 22%) of crystallization during the deposition. Furthermore, the crystallization releases heat in the system that increases the temperature of the deposited bead gradually up to 20 ℃.
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Submitted on : Tuesday, March 10, 2020 - 11:00:58 AM
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Shahriar Bakrani Balani. Additive manufacturing of the high-performance thermoplastics: Experimental study and numerical simulation of the Fused Filament Fabrication. Materials. Institut National Polytechnique de Toulouse, 2019. English. ⟨tel-02503729⟩

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