Numerical simulations of concrete processing: From standard formative casting to additive manufacturing

Roussel, Nicolas; Spangenberg, Jon; Wallevik, Jon Elvar; Wolfs, Rob

doi:10.1016/j.cemconres.2020.106075

Cited by 75 publications

(28 citation statements)

References 61 publications

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“…To be specific, when the material stress reaches the yield stress, the hydrate bridges between percolated cement particles break and they flow. As a consequence, the printable materials display a viscous behavior and the shear rate is proportional to dynamic yield stress based on the plastic viscosity (Buswell et al, 2020;Roussel, 2018;Roussel et al, 2012Roussel et al, , 2020. Once the structure reaches the critical weight load, it will collapse.…”

Section: Computational Uniaxial Compression Testmentioning

confidence: 99%

“…Consequently, this non‐uniform gravitational load may threaten the overall stability of the object being printed, allowing fewer layers to be printed than otherwise expected. However, this influence has not been studied in any of the previous prediction models (Kruger Cho, et al., 2019; Kruger, Zeranka, et al., 2019; Roussel et al., 2020; Suiker et al., 2020; Wolfs et al., 2018, 2019). To account for the continuous printing process, each printing layer is divided into several sequential printing pieces (as indicated in Figure 6).…”

Section: Model Developmentmentioning

confidence: 99%

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A discrete lattice model for assessment of buildability performance of 3D‐printed concrete

Chang

Chen

et al. 2021

Computer aided Civil Eng

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In this work, the lattice model is applied to study the printing process and quantify the buildability (i.e., the maximum height that can be printed) for 3D concrete printing (3DCP). The model simulates structural failure by incorporating an element birth technique, time‐dependent stiffness and strength, printing velocity, non‐uniform gravitational load, localized damage, and spatial variation of the printed object. The model can reproduce the plastic collapse failure modes reported in the literature. In this research, three main contributions for 3DCP modeling work can be found. A new failure criterion is proposed and adopted to improve the estimation of critical printing height; the element birth technique is utilized to mimic the continuous printing process and study the impact of non‐uniform gravitational load; variability of a printed structure is modeled through the inclusion of disorder during mesh generation and Gaussian distributions of material properties. Using this model, parametric analyses on non‐uniform gravitational load and material variation are conducted to assess their impact on the failure–deformation response and the critical printing height. Finally, the model is validated by comparison with two 3D printing experiments from the literature. The proposed lattice model can reproduce the correct failure‐deformation modes of two types of structures commonly used for buildability quantification: A 3D‐printed hollow cylinder and a square wall layout. Lattice modeling of the square structure yields a relative difference of around 10% with the experimental printing height. For the cylinder structure, the predicted radial deformation and corresponding height show good agreement with the experimental data; the model yields a 41.38% overprediction of the total number of printing layers, compared with the experimental data. Possible reasons for the quantitative discrepancy are discussed.

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Section: Computational Uniaxial Compression Testmentioning

confidence: 99%

Section: Model Developmentmentioning

confidence: 99%

A discrete lattice model for assessment of buildability performance of 3D‐printed concrete

Chang

Chen

et al. 2021

Computer aided Civil Eng

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“…In the researchers' quest to understand and improve extrusion-based 3DCP, they recently develop various numerical models that simulates the process [6]. For example, Wolfs et al [7,8] used finite element models to investigate the early age mechanical behaviour of printed concrete as well as the structural collapse during the material extrusion printing process.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of multi-layer 3D concrete printing

Spangenberg

Silva²,

Comminal³

et al. 2021

RILEM Tech Lett

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This paper presents a computational fluid dynamics model fit for multi-layer 3D Concrete Printing. The numerical model utilizes an elasto-visco-plastic constitutive model to mimic the flow behaviour of the cementitious material. To validate the model, simulation data is compared to experimental data from 3D printed walls. The obtained results show that the numerical model can reproduce the experimental results with high accuracy and quantify the extrusion load imposed upon the layers. Such load is found to exceed the material’s yields stress in certain regions of previously printed layers, leading to layer deformation/flow. The developed and validated numerical model can assist in identifying optimal printing strategies, reducing the number of costly experimental print failures and human-process interaction. By doing so, the findings of this paper helps 3D Concrete Printing move a step closer to a truly digital fabrication process.

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“…Therefore, they may somewhat lack genuine interpretation of the actual numerical outcome or reliability. In the context of cementitious materials, some numerical studies have also been conducted to numerically simulate cementitious paste suspensions or even concrete suspensions [2,3,[5][6][7][8][9]13,[30][31][32][33][34][35]. However, in most of these works, it is unclear how reliable the numerical simulations actually are, independent of whether a mismatch or good match was found, let alone to know the actual influence of the rheological input with regard to the numerical outcome.…”

Section: Introductionmentioning

confidence: 99%

Numerical Reliability Study Based on Rheological Input for Bingham Paste Pumping Using a Finite Volume Approach in OpenFOAM

et al. 2021

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Rheological quantification is important in many industries, the concrete industry in particular, e.g., pumping, form filling, etc. Instead of performing expensive and time-consuming experiments, numerical simulations are a powerful means in view of rheological assessment. However, due to the unclear numerical reliability and the uncertainty of rheological input data, it is important for the construction industry to assess the numerical outcome. To reduce the numerical domain of cementitious suspensions, we assessed the numerical finite volume simulations of Bingham paste pumping flows in OpenFOAM. We analysed the numerical reliability, first, irrespective of its rheological input by comparison with the literature and theory, and second, dependent on a certain rheological quantification by comparison with pumping experiments. Irrespective of the rheological input, the numerical results were significantly accurate. Dependent on the rheological input, a numerical mismatch, however, existed. Errors below 1% can be expected for proposed numerical rules of thumb: a bi-viscous regularisation, with pressure numbers higher than 5/4. To improve bias due to uncertain rheology, a rheological configuration close to the engineer’s aimed application should be used. However, important phenomena should not be overlooked. Further assessment for lubrication flows, in, e.g., concrete pumping, is still necessary to address concerns of reliability and stability.

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Numerical simulations of concrete processing: From standard formative casting to additive manufacturing

Cited by 75 publications

References 61 publications

A discrete lattice model for assessment of buildability performance of 3D‐printed concrete

A discrete lattice model for assessment of buildability performance of 3D‐printed concrete

Numerical simulation of multi-layer 3D concrete printing

Numerical Reliability Study Based on Rheological Input for Bingham Paste Pumping Using a Finite Volume Approach in OpenFOAM

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