QuadWire: An extended one dimensional model for efficient mechanical simulations of bead-based additive manufacturing processes

This paper presents the basis of a new mechanical model named QuadWire dedicated to efficient simulations of bead-based additive manufacturing processes in which elongated beads undergoing significant cooling and eigenstrain are assembled to form 3D parts. The key contribution is to use a multi-particular approach containing 4 particles per material point to develop an extended 1D model capable of capturing complex 3D mechanical states, while significantly reducing computation time with respect to conventional approaches. Indeed, 3D models usually require at least 3 to 4 elements across the bead section, which results in fine discretization along the tangential direction to avoid conditioning issues, and therefore very fine mesh of the entire 3D part. In the QuadWire model, the bead height and thickness are internal dimensions, enabling a significantly coarser mesh along the tangential direction. Thus, although the QuadWire has 12 degrees of freedom per material point instead of 3 for classical models, the total number of degrees of freedom is reduced by several orders of magnitude for large parts. The proposed model is classically developed within the framework of the principle of virtual power and standard generalized hyperelastic media (i.e., finite strain theory), which necessitates a thermodynamic analysis. Furthermore, the proposed approach includes native and manageable kinematic constraints between successive beads so that the stress state properly evolves during fabrication. Finite element analysis is used for numerical implementation under infinitesimal strain assumption for the sake of simplicity, and the QuadWire stiffness parameters are optimized so that the mechanical response fit conventional 3D approaches. To validate and demonstrate the capabilities of the proposed strategy, the evolution of displacements and stresses in fused deposition modeling of polylactide is simulated.