YAN Xin, WANG Shenru, LIU Siqin, et al. Research progress in multi-scale modeling of processing mechanics and mechanism in additive manufacturing technology of continuous fiber reinforced thermoplastic composites[J]. Acta Materiae Compositae Sinica, 2024, 41(9): 4502-4517. DOI: 10.13801/j.cnki.fhclxb.20240722.005
Citation: YAN Xin, WANG Shenru, LIU Siqin, et al. Research progress in multi-scale modeling of processing mechanics and mechanism in additive manufacturing technology of continuous fiber reinforced thermoplastic composites[J]. Acta Materiae Compositae Sinica, 2024, 41(9): 4502-4517. DOI: 10.13801/j.cnki.fhclxb.20240722.005

Research progress in multi-scale modeling of processing mechanics and mechanism in additive manufacturing technology of continuous fiber reinforced thermoplastic composites

Funds: National Natural Science Foundation of China (12372106; 52205003); Zhejiang Provincial Natural Science Foundation of China (LD22E050011); Ningbo Key Projects of Science and Technology Innovation 2025 Plan (2022Z070; 2023Z054)
More Information
  • Received Date: May 30, 2024
  • Revised Date: June 26, 2024
  • Accepted Date: July 04, 2024
  • Available Online: July 22, 2024
  • Continuous fiber-reinforced thermoplastic composites offer exceptional mechanical and chemical properties, attracting widespread attention in both academia and industry. To meet the automation requirements for high-performance complex structural components, additive manufacturing technologies for continuous fiber-reinforced thermoplastic composites have garnered significant interest. These manufacturing methods include Fused Deposition Modeling and automated fiber placement. The additive manufacturing process involves multi-scale physical phenomena, presenting a complex interplay that is not yet fully understood. The inherent properties of thermoplastic polymers, such as their high melting points and viscosities, further complicate processing, posing substantial challenges in the control of manufacturing processes. Addressing the intricate mechanical challenges within the manufacturing process can be facilitated through the application of multi-scale process mechanics simulations. The integration of these simulations with theoretical and empirical research aids in forging a clear correlation between manufacturing process parameters and the quality of the final product. This provides theoretical support for optimizing process parameters and equipment module design. However, the implementation of multi-scale process simulation requires in-depth comprehension and precise description of physical phenomena. It also involves the design of sophisticated algorithms and the construction of intricate models, thereby increasing the difficulty and challenge of the simulation. This paper reviews recent studies employing various numerical modeling approaches to investigate the processing mechanisms of continuous fiber reinforced thermoplastic composites during the AFP and FDM processes. It also outlines potential promising directions in the field.
  • Objectives 

    Continuous fiber-reinforced thermoplastic composites (CFRTCs) have vast application potential due to their excellent mechanical and chemical properties. With the development of automation technology, automated additive manufacturing techniques, such as automated fiber placement (AFP) and 3D printing, have garnered significant attention. However, due to the multi-level characteristic of composite, the manufacturing process of CFRTPCs involves the coupling of multiple scales and physical fields, which makes the understanding of the forming mechanism highly challenging, thereby complicating the optimization of the manufacturing process. Consequently, researchers have explored the mapping relationships between the process parameters and the relevant physical phenomena during the forming process, from a process mechanics perspective. By integrating theoretical and experimental studies, it is possible to establish correlations between process parameters and the quality of the formed products, thereby providing theoretical support for the design of optimized process parameters and equipment modules. However, due to the multi-scale and multi-physics nature of composite forming process, there are lots of studies focusing on a variety of phenomena and methods, making it difficult for researchers to quickly identify the suitable approaches for their specific interests. Therefore, this paper reviews recent advances in the multi-scale simulation methods for studying the mechanisms of CFRTCs during the manufacturing processes of AFP and 3D printing, aiming to provide scientists and engineers in the field of composites with a valuable reference for the modeling methods of process mechanics.

    Methods 

    This review summarizes the recent advancements in the simulation methods at various scales for studying the mechanisms of CFRTCs during the forming processes of AFP and 3D printing. It first introduces the typical equipment and forming processes of the additive manufacturing for CFRTCs. Subsequently, it analyzes the progress in the simulation of process mechanics at the micro, meso, and macro scales, and outlines the approaches for coupling simulation methods across different scales. Finally, the review explores strategies and future trends in integrating data-driven approaches, digital twins, and multi-scale process mechanics simulations.

    Results 

    The multi-scale simulation analysis of the additive manufacturing process for CFRTCs offers insights into the forming mechanisms that are difficult to observe experimentally, which provides a guiding framework for optimizing the forming process and enhancing the mechanical properties. Based on the current state of research on multi-scale process simulation for additive manufacturing of CFRTCs, the following conclusions are drawn.Conclusions: Thermoplastic composites undergo a transition from solid to viscoelastic state and back to solid during the additive manufacturing processes. Hence, their mechanical behaviors are closely linked to the thermal, flow, and phase transformation fields during the manufacturing process, which should be analyzed from a multi-physics coupling perspective. While the methods of macroscopic process mechanics often rely on the phenomenological models, they have the advantage in conveniently considering the real effects of processing on the defect formation, and the simulation results could be easily compared and adjusted against the macroscopic experimental outcomes, because the macroscopic methods operate within the same temporal and spatial dimensions as the final composite products. In contrast, although the microscopic and mesoscopic models, stemming from the fundamental physical theories, could accurately describe the physical phenomena, they are limited by the temporal and spatial dimensions and cannot account for the numerous macroscopic disturbances. Consequently, their simulation results are typically challenging to apply in guiding the manufacturing processes under macroscopic conditions. Multiscale process mechanics aim to integrate the strengths of methods at various temporal and spatial scales, thereby providing process analysis solutions that are both physically meaningful and practically applicable to the manufacturing guidance. Therefore, multiscale process mechanics play a crucial role in advancing the manufacturing processes, particularly in the complex composite processing involving multiple scales, physical fields, materials, and interface characteristics. With the technological advancements, the integration of multiscale process simulation with the data-driven algorithms and digital twins promises greater development opportunities for the rapid customization, process design, and efficient production of CFRTCs.

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