Effect of blade geometry on the powder spreading process in additive manufacturing--颗粒学报PARTICUOLOGY

Yang, D., Chu, X., & Liu, Q. (2024). Effect of blade geometry on the powder spreading process in additive manufacturing. Particuology, 94, 345-355. https://doi.org/10.1016/j.partic.2024.08.018

Effect of blade geometry on the powder spreading process in additive manufacturing

Deze Yang^a, Xihua Chu^a *, Qipeng Liu^b

a School of Civil Engineering, Wuhan University, Wuhan, 430072, China
b Jiangxi Key Laboratory of Forming and Joining Technology for Aerospace Components, Nanchang Hangkong University, Nanchang, 330063, China

10.1016/j.partic.2024.08.018

Volume 94, November 2024, Pages 345-355

Received 11 June 2024, Revised 28 August 2024, Accepted 29 August 2024, Available online 10 September 2024, Version of Record 19 September 2024.

E-mail: Chuxh@whu.edu.cn

Highlights

• A round blade causes a higher density than an inclined blade or vertical blade.

• Increasing round blade radius can increase packing density of the powder bed.

• Improving smoothness of blade shape transition can improve the powder bed quality.

Abstract

In powder-bed-based additive manufacturing, the quality of the powder bed is closely related to the geometry of the blade used during the powder spreading process. In this study, the spreading process with the vertical blade, inclined blade, and round blade with different radii was performed by discrete element method to investigate the effects of blade geometry on powder spreading. The results show that at the same spreading parameters, the round blade caused the highest density than inclined blade and vertical blade. Increasing the round blade radius can improve the packing density of the powder bed, but it has little effect on the uniformity. The increase in packing density is related to the transitional smoothness of the blade surface at the entrance of the powder bed. The smoother the shape transition of the blade surface at the powder bed entrance, the powders enter the powder bed more gently, so more powders enter the powder bed, resulting in higher packing density. The results may provide suggestions for improving the laser melting process.

Graphical abstract

Keywords

Additive manufacturing; Powder spreading; Blade geometry; Discrete element method

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