Numerical simulation of the flow behavior and powder spreading mechanism in powder bed-based additive manufacturing

The flow behavior of the powder layer significantly affects subsequent dynamic behavior and final quality of the parts fabricated via powder bed-based additive manufacturing. High powder layer quality is the key scientific problem and technical difficulty, however, the dynamic flow behavior of powder particles and its relationship between powder layer quality were not well understood. In this paper, the influences of typical factors including process parameters (relative layer height and blade velocity) and powder properties (particle size and surface energy coefficient) on powder layer quality of polyamide 6 were systematically investigated by discrete element method to understand the mechanism of the powder layer packing behavior at the particle scale. The packing density, structure uniformity, normalized layer thickness, and surface uniformity were introduced to quantitatively characterize the powder layer quality. The mechanisms at the particle scale, including the blocking of particle, force arch, particle velocity distribution, and cohesion effect were discussed in detail. The results showed that a decreasing value particle size/layer height can effectively weaken the blocking effect of particles, improving the continuity and stability of powder flow and inducing a dense and uniform powder layer. The particles with high average velocity in the gap between the blade and baseplate will move forward after the blade leaves, significantly reducing the layer thickness and packing density. Meanwhile, the cohesion force was determined by the particle size and surface energy coefficient, and the cohesion effect dominated the flow behavior of the particles with a small particle size d = 10μm or a large surface energy coefficient γ = 0.2mJ/m2. These findings can provide useful guidance in understanding the flow behavior at the particle scale and improving the powder layer quality. [Display omitted] •The effect of the van der Waals force on powder flow behavior is considered.•The quality of powder layer is quantitatively evaluated by four metrics.•Powder flowability increases with a decreasing value particle size/layer height.•Cohesion effect induces aggregation of particles with d = 10 μm or γ = 0.2 mJ/m2.