Warping Analysis in Laminated Object Manufacturing Process

Abstract

This study presents an analysis of warping that occurs in the laminated object manufacturing process. Based on the study of thermal-mechanical behavior of the adhesive and its effect on the laminated materials, the cause of warping, the relationship between temperature and adhesive viscosity, and the adhesive connecting intensity is investigated. A heat transfer mathematical model and finite difference solution algorithm was developed to calculate the intralaminar thermal force induced by the material addition in the processing of laminated object manufacturing. The results of the model prediction were compared to available experimental data. Simulation of intralaminar thermal force and case studies show that the processing parameters, such as roller temperature, speed, and contact pressure, the mechanical properties of laminated material and adhesive will all contribute to the formability and warping of the laminated prototype. An optimal combination of the processing parameters may reduce the undesired warping effect.