Amir Rahimi - Department of Mechanical Engineering, K.N. Toosi University of Technology, Iran
Jamal Zamani - Department of Mechanical Engineering, K.N. Toosi University of Technology, Iran

Fused Deposition Modeling and Sintering (FDMS) is one of the indirect and emerging processes of Additive Manufacturing (AM) for the production of metal parts, which is a combination of AM process and Metal Injection Molding (MIM). This study laboratory made a raw material (Feed Stock) composing of high percentage of metal powder (particle in nano-scale) and polymeric materials; and then, designed an extruder to simulate melting and extruding process by Computational Fluid Dynamic (CFD). The different variables such as the nozzle diameter (D) of ۱, ۲, ۳ and ۴ mm and compression zone length (L۲) of ۱۰۰, ۲۰۰ and ۳۰۰ mm were simulated to investigate their impacts on flow rate and required torque to rotate screw. The findings showed that components of feed stock for high physical and mechanical properties of FDMS should account for ۵۵ wt.% of paraffin wax, ۲۵ wt.% of polypropylene, ۱۵ wt.% of carnauba wax and ۵ wt.% of stearic acid with optimum percentage of metal powder of ۹۰ wt.%. Also, the optimum value of extruder diameter and compression zone length were ۲mm and ۲۰۰ mm, respectively.

Additive Manufacturing, AISI ۴۶۰ steel alloy, Extruder Screw, Fused Deposition Modeling and Sintering