International Journal For Technological Research In Engineering

Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

2D NOZZLE DESIGN TECHNIQUE IN MATLAB AND EXTENTION

RESEARCH USING FDM
Kavita Gambhir1, Dr. RK Gupta2
1 2
M. Tech, HOD, Mechanical Engineering, GITM, Bilaspur, MDU Rohtak

ABSTRACT: In an era of manufacturing design work, it is quantity of thrust for the given close pressure and
very important work assignment for designing of nozzle. combustion chamber parameters.
This device is designed to control the direction or
characteristics of a fluid flow (especially to increase 1.4 Use of nozzle
velocity) as it exits (or enters) an enclosed chamber. A As nozzle is often a pipe or tube of varied cross sectional
nozzle is often a pipe or tube of varying cross sectional area space, used to direct or modify the flow of a fluid (liquid or
and it can be used to direct or modify the flow of a fluid. gas).Nozzles are often used to manage the speed of flow,
One of the challenging task in aerospace industries and speed, direction, mass, shape, and/or the pressure of the
mechanical industries is the design/analysis and realization stream that emerges from them. Nozzles are used to regulate
of complex nozzle systems for solid rocket motors of satellite the flow of fluid. The area unit is found at the tip of a hose or
launchers, missiles, etc., Existing empirical relations have pipe from which liquid or gas substances are discharged.
limitations to design such complex nozzle systems. The Different nozzles area unit are created for numerous
proposed technique gives the ideal nozzle geometry using applications.
the method of characteristics for a Quasi-2D Diverging
Nozzle. Using 2D nozzle flow relations, an optimal throat 1.5 Basics of Nozzle design &it’s Technique
area is found that will produce the max amount of thrust An aviation vehicle, whether an aviation plane, orbital
for the given ambient pressure and combustion chamber dispatch vehicle or interplanetary shuttle, is quickened by an
parameters. In proposed technique, nozzle exit area is impetus framework to a speed managed by prerequisites
found that produces the max amount of thrust. After particular to the vehicle's central goal. In all cases, a spout is
simulation, the proposed technique finds the error Area, utilized to remove the greatest push from high-weight
error Mach. Further, Shape of the said nozzle has been debilitate gasses produced by the impetus framework. In case
calculated using quasi 2D Diverging technique or that of supersonic nozzle, which is operating at pressure ratios
resembles the shape and length in terms of Mach Number well below its design point, a shock forms inside the nozzle
P/P and Nozzle respectively. and flow downstream of the shock separates from the nozzle
Keyword: Nozzle, Quasi-2D Diverging Technique, CFD, walls. Even though this flow is very basic, it remains poorly
MATLAB understood. This is illustrated by the large discrepancy
between predictions of quasi-one-dimensional in viscid
I. INTRODUCTION theory and the actual behavior of the flow. [6]
1.1 Basic of nozzle design
A nozzle is a device designed to regulate the direction or II. DISCUSSION ON EXTENSION OF NOZZLE DESIGN
characteristics of a fluid flow (especially to extend velocity) 2.1 Fused Deposition Modeling
because it exits (or enters) an inside chamber or pipe. A Fused deposition modelling (FDM) is a common additive
nozzle is often a pipe or tube of variable cross sectional area, manufacturing (AM) method for creating polymer parts.
and it can modify the flow of a fluid (liquid or gas).[9] FDM builds parts additively by depositing a small bead of
molten plastic through an extrusion head onto a work
1.2 Computational Fluid Dynamics (CFD) For Nozzle. platform. The nozzle (or platform) moves via computer
The goal of a nozzle is to increase the mechanical energy of control to lay down a plastic pattern on the platform.
the flowing medium at the expense of its pressure and Complete parts are built by laying down successive patterns
internal energy. Nozzles can be delineated as merging one layer at a time. While the lead time to produce AM parts
(narrowing down from a good diameter to a smaller diameter via FDM is relatively short, the per unit manufacturing time
within the direction of the flow) or divergent (expanding is much longer than conventional mass production
from a smaller diameter to a bigger one). techniques. This is partly due to the fact the extrusion head,
which has a small diameter nozzle, has a low volumetric
1.3 Quasi-2D Diverging Nozzle deposition rate. In conventional FDM the nozzle diameter is
This program gives the ideal nozzle design based on small to maximize the resolution of each layer. Three main
Computational fluid dynamics. Assume the gas is exhausting options exist to increase the build rate: i) increase the speed
from a combustion chamber that has no mass flow rate. of the horizontal movements; ii) minimize the material of the
Using Quasi-2D Diverging nozzle flow relations, an part; or iii) increase the diameter of the nozzle. This paper
optimum throat space is found that can manufacture the GHB introduces a concept for adapting an existing AM system

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

which employs a variable diameter nozzle for the fused In practice, extrusion paths like the one shown in Figure 2.1
deposition of polymers. The variable nozzle allows the print are prevented by the tool path generation software due to the
resolution and the build speed to become independent overlapping projections of the nozzle path as it enters and
variables which may be optimized. exits the corner. To verify this statement, an isosceles
triangle with a 15° vertex was printed in the horizontal plane
2.2 Variable fused deposition modeling (vfdm) on a Dimension 1200 BST FDM machine. The slicing and
2.2.1 Impacts on horizontal resolution tool paths were generated using Stratasys’ proprietary
FDM nozzles utilize circular orifices to take advantage of the software Catalyst®EX. According to Equation 1, the
axisymmetric properties in the horizontal plane. The benefit calculated minimum error is 0.67 mm while the measured
of this is that the nozzle does not need to be kept normal to error was 3.87 mm. Therefore it is evident that the errors
the extrusion path. The disadvantage is that all angles will associated with printing high aspect ratio features have been
have radii greater than or equal to the radius of the nozzle as highly underestimated and the need for small diameter
shown in Figure 2.1. nozzles is even greater. VFDM allows for a larger diameter
orifice to be used for infill, where geometric error is less
important, and smaller diameters for the exterior shell where
high resolution is desirable. The authors believe that by using
this process it is possible to improve the quality of FDM
parts while increasing build speed.

2.3 Impacts on extrusion time

For large parts, with a high percentage of infill, the extrusion
time during a build is a function of the nozzle diameter and
the geometry of the part.For the purposes of an example,
consider a 30, 60, 90° triangle which is 1 unit thick and has
dimensions as defined in Figure 2. 3.

Figure 2.1: Geometric error due to circular nozzle

The geometric error can be calculated using Equation 1
below:
𝑟
𝐸𝑟𝑟𝑜𝑟 = 𝜃
−𝑟
sin 2
Where r = radius of the extrusion orifice and θ = angle of Figure 2.3: Plan view geometry of 30, 60, 90 triangle for
modelled geometry. extrusion time saving analysis
Assuming the part is 100% solid and the nozzle diameters,
Figure 2.2 shows the relationship between the geometric feed rate and layer thicknesses are known, it is possible to
error and the intended angle for normalized nozzle radii. The calculate the extrusion time as a function of part volume
bottom line represents a radius of one unit while the middle (Equation 2).
and top line represent radii two and three times larger
respectively. As can be seen on the graph the error is small 𝑣𝑜𝑙𝑢𝑚𝑒
𝐸𝑥𝑡𝑟𝑢𝑠𝑖𝑜𝑛 𝑡𝑖𝑚𝑒 = 𝐷×𝑓×𝑙
(2)
for large angles but grows significantly for angles less than
60°. For 60° angles the error is at least equal to the orifice
radius Where volume = the volume of the part (mm³), D = the
nozzle diameter of the part (mm), f = nozzle feed rate (mm/s)
and l = layer thickness.

If the nozzle is able to use a small diameter for the outer

shell(s) and a larger diameter for the infill then Equation 2
becomes:
𝑣𝑜𝑙𝑢𝑚 𝑒 𝑠ℎ 𝑒𝑙𝑙 (𝑠) 𝑣𝑜𝑙𝑢𝑚 𝑒 𝑖𝑛𝑓𝑖𝑙𝑙
𝐸𝑥𝑡𝑟𝑢𝑠𝑖𝑜𝑛 𝑡𝑖𝑚𝑒 = + (3)
𝐷1×𝑓×𝑙 𝐷2×𝑓×𝑙
Where volumeshell(s) = volume of the outer layer(s) of the part,
volumeinfill = volume of the inside of the part, D1 = small
nozzle diameter, D2 = large nozzle diameter.
Figure 2.2: Graph showing minimum geometrical error of an Using the following parameters, D1 = 0.5 mm, D2 = 1.0 mm,
angle printed with a circular nozzle f = 25 mm/s, and l = 0.5, a graph was created showing the

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

extrusion times for the 30, 60, 90° triangular prism over a DVNs are mechanically simpler than CVNs and are therefore
range of volumes and variable nozzle diameter relatively simple to manufacture at the sub-millimeter scales
configurations. Configuration A (the steepest line) shows the required. Possible solutions to DVNs are interchangeable
extrusion time required if only a nozzle of diameter 0.5 mm nozzles and multiple stage nozzles. Interchangeable nozzles
is used. Configuration D (the shallowest line) shows the could sit in a carousel and automatically change via
extrusion time for a fixed 1.0 mm nozzle. C and B show the computer control. This concept was abandoned due to the
extrusion times for parts with one and two layer thick shells difficulties associated with the nozzles into and out of the
respectively. polymer flow stream. The multiple stage nozzle works by
moving nested inserts inside the nozzle. The multiple stage
A B C D nozzle was found to be relatively easy to implement while
8E+4
allowing circular orifices and uninterrupted polymer flow.
The design for a two stage nozzle is presented in the next
Extrusion time (s)

6E+4
section.
4E+4
2.6 Two stage nozzle design
The two stage nozzle consists of an inner and outer nozzle
2E+4
each with fixed orifice diameters. The inner nozzle is
actuated by a solenoid, and in its lowest position is nested
0E+0 firmly against the inner surface of the outer nozzle,
0E+0 1E+5 2E+5 3E+5 4E+5 5E+5 restricting the flow through the smaller orifice. When the
Part volume (mm³) inner nozzle is lifted a secondary melt chamber is formed
Figure2.4: Graph showing the extrusion times as a function which allows multiple polymer flow streams to coalesce
of part volume for different nozzle configurations before leaving the larger orifice as shown in Figure 2.5.
As can be seen by the small difference between
configurations B, C and D, the amount of time required to
add high resolution outer shells is insignificant for large
volume builds. In the case of the 30° vertex, replacing the 1.0
mm nozzle with the 0.5 mm nozzle reduces the theoretical
error from 1.43 mm to 0.72 mm. In practice, due to the way
the tool paths are calculated, the improvements in resolution
will be far greater. It should be noted here that the same
extrusion time savings could be made by utilizing two
separate extrusion heads with different fixed diameter
nozzles. However, the problem with this solution is the time
taken to switch extrusion heads and the extra room required
on the positioning rack. This problem is magnified for
machines with multiple material capabilities.

2.5 Concepts for VFDM

Possible concepts for VFDM nozzles can be placed into two
main categories: continuously variable nozzles (CVNs) and
discretely variable nozzles (DVNs). CVNs allow much more
freedom in choosing the print resolution and build speed and
allow for the possibility of size changes whilst printing. The
main disadvantage of CVNs is the mechanical complexity
and the necessary design compromises that result. Possible
solutions reviewed by the authors include mechanical irises,
sliding jaws and smart materials. All CVN solutions analyzed
required that the orifice be an approximation of a circle. This Figure 2.5: Two stage nozzle with a) small diameter orifice
increases the error relative to a circle of the same area and and b) large diameter orifice
may result in orthotropic extrusion properties. For example This concept achieves many of the objectives of VFDM but
think of a square moving in a direction parallel with its sides, also has a number of significant drawbacks. Assuming the
and then imagine the square moving diagonally. Obviously outer shell of each layer is deposited first, there will be a
the track will be wider for the diagonal movement. Another small delay required before the infill can start as the
difficulty in designing a CVN is scaling down the actuating secondary chamber must be filled with molten polymer. The
mechanisms to a size desirable for typical FDM applications. second major drawback is that polymer in the secondary
The design and build of CVNs is likely to be the topic of chamber is likely to be pushed out as the inner nozzle moves
future research by the authors. back into the lower position. This not only wastes material

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

but will add extra build time as the nozzle moves to a III. TOOL PATH GENERATION
designated discharge point.Notwithstanding these problems it It is the authors’ intention to develop an advanced tool path
is expected that the two stage nozzle will reduce the build generation algorithm in parallel with future developments in
time for large solid high resolution parts. The following VFDM. The tool path generation described in this paper is a
section describes how the nozzle is integrated into a RapMan more basic method which will be used for testing the two
3.0 3D printer from Bits from Bytes (BfB). stage nozzle concept.
3.1 Standard printing procedure
2.7 Two Stage Nozzle Design A summarized standard procedure for printing parts on a
2.7.1 RapMan 3D printers RapMan machine is as follows:
The RapMan 3.0 is a FDM machine based on the open source  Generate an STL file from a CAD program.
RepRap project and is shown in Figure 2.6. The low cost and  Upload the STL file into Bits from Bytes Axon
open structure of the RapMan makes it highly suitable for (Skeinforge).
research related modification.  Generate the G-code with the .bfb extension.
 Upload the .bfb file onto an SD card.
 Insert the SD card into the RapMan card reader and
run the file.
The standard input file to most FDM systems is the
stereolithography or STL file. STL files describe the surface
geometry of parts by using a triangular mesh. The BfB Axon
program is a user friendly front-end to the more complicated
but versatile Skeinforge open source software. Skeinforge is
a tool chain composed in Python script that allows the user to
control many of the parameters that generated the tool path
G-code. G-code is the common name given to the computer
numeric control programming language adopted by many
automated machine tools. While generic G-code generators
Figure 2. 6: Unmodified RapMan 3.0 from Bits for Bytes exist, many manufacturing technologies use machine specific
The VFDM extruder is designed to replace the original G-codes which require post processing in order to be used in
RapMan extruder with minimal changes. The standard other machines. The RapMan uses its own form of G-code
RapMan heating system will be changed from a fixed which is, amongst other things, differentiated by the
resistance wire and fire cement configuration to a removable extension .bfb. The next section describes how the
aluminium block which contains two power resistors. One of Skeinforge settings were adjusted for the two stage nozzle
the power resistors is connected to the RapMan control board and how the BfB G-code was subsequently altered to allow
along with a thermistor for temperature control. The other for the nozzle mode changes.
power resistor is connected to an external circuit to enable a
base heating load giving greater temperature control via the IV. PROPOSED WORK
thermostat, see Figure 2.7. 4.1 Solution Methodology: The exploration proposes and
builds up the down to earth advancements for the
configuration, testing, and investigation of the spouts utilized
as a part of the QUASI-2D process.
• Develop a MATLAB programming skilled to create
pragmatic diagrams for the QUASI-2D, prepare and produce
the 2D suggested spout form, utilize the Computational Fluid
Dynamics (CFD) .Further make a air flow to nozzle for test
the shape of nozzle.
4.2 Source of Data and Methodologies:The investigative
methodology to be embraced will fundamentally be guided
by the points highlighted previously. These include:
• Gather QUASI-2D process data from exploration with the
primary target concentrated on the spout outline,
• Use the compressible stream hypothesis to construct a
brought together hypothesis for the computation of particles
speed in the QUASI-2D process,
• Use the general hypothesis, called the 'Strategy for
Characteristic' (MOC) to construct a model for creating a
two dimensional 'least length' spout for various gas molecule
Figure 2.7. Two stage nozzle and heating assembly extensions.
• Develop an effective MATLAB computational

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

programming that will handle all building counts and 5.3 Simulation Steps
yearning parameters for the QUASI-2D spout, and utilize the First, we initiate with nozzle’s file from the current folder
Computational Fluid Dynamics (CFD). and run the simulation.
From this simulation, we get value of error area& error
4.3 MacCormack Plan: The unequivocal MacCormack mach.
calculation (MacCormack, 1984) utilizes two stages to After that Fig 5.2, 5.3 & 5.4 will show up.
progress as a part of time, one is the indicator and the other is Second, Click on Noz_mesh from the current folder and run
the corrector. It is a arrangement in both space and time. In the Simulation.
the indicator step the flux vector at a specific face is figured From this simulation, we get the ans= mesh done.
utilizing the properties of the forward cell, though in the Third, click on the nozcfd from the current folder and run the
corrector step the property estimations to be utilized are the simulation.
ones in respect to the retrogressive cell. Then, we see that some values are running from K=1 to
K=499. When its reach to K=500, some graph will show
4.4 Objectives: Mat lab Simulation based on Quasi-2D again. (Fig 5.5 & 5.6).
Diverging Technique.
a) Solve for the nozzle exit area that produces the max 5. 4 Simulation results from MATLAB
amount of thrust.
b) Use the method of characteristics to solve for the shape of
the said nozzle.
c) Automatically make curvilinear mesh for simulating the
nozzle
d) Solves the Euler equations on the mesh using the Mac
Cormack finite volume method.
e) Plots the result
The filament guide also acts as the connection between the
solenoid and the inner nozzle. The filament feed mechanism
will be moved slightly to allow the solenoid to be positioned
directly above the inner nozzle.The RapMan uses open
source software Skein forge, to generate the required G-code.

V. SIMULATION AND RESULTS

5.1 Simulation Tools Fig 5.1 First GUI
Many specialists and researchers overall use MATLAB to
dissect and outline the frameworks and items changing our
reality. MATLAB is in car dynamic wellbeing frameworks,
interplanetary shuttle, wellbeing observing gadgets, brilliant
force matrices, and LTE cell systems. It is utilized for
machine learning, signal handling, picture preparing, PC
vision, interchanges, computational money, and control
outline, apply autonomy, and considerably more.

5.2 Simulation Parameters

Tc = 2000;
% Temperature in the combustion chamber (K)
Pc = 1.2e6;
% Pressure in the combustion chamber (Pa) Fig 5.2 Maximum Thrust Nozzle Design
Pamb = 101e3;
% ambient pressure (Pa)
Tamb = 300;
% ambient temperature (K)
Gamma = 1.25;
% Ratio of Specific Heats Cp/Cv (Gamma)
W = 25.4;
% Molecular weight of gas (kg/kmol)
Width = .1;
% Nozzle width (meters)
Hth = .025;
% Throat height (meters) Fig 5.3 Mach number and P/P vs Nozzle Length

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

parameters. After Simulation, This technique finds a nozzle

exit area that produces the max amount of thrust as shown in
fig 5.2. After run the simulation, this technique finds the
error_Area= -3.1045, error_Mach= -4.2719e-004. Further,
Shape of the said nozzle has been calculated using quasi 2D
Diverging technique or that resemble the shape and length in
terms of Mach Number P/P and Nozzle respectively.

VI. CONCLUSION AND FUTURE WORK

One of the challenging task in aerospace industries and
mechanical industries is the design/analysis and realization
of complex nozzle systems for solid rocket motors of
satellite launchers, missiles, etc., Existing empirical relations
have limitations to design such complex nozzle systems. The
Fig 5.4 Static thrust vs. Exit Area proposed technique gives the ideal nozzle geometry using the
Program to extrapolate the data points from nozzle design method of characteristics for a Quasi-2D Diverging Nozzle.
and make a uniform grid spacing in the x-direction (Change Using 2D nozzle flow relations, an optimal throat area is
nothing). Simply run this script. Find the minimum spacing found that will produce the max amount of thrust for the
given by the method of characteristics and set as the dx given ambient pressure and combustion chamber parameters.
value. Future work is directed towards the qualification testing of
the nozzle system under various environmentalconditions
like temperature, humidity and cyclic loading. Advancement,
willbe carried out in constructing 3-D simulation of nozzle in
MATLAB.

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International Journal For Technological Research In Engineering
Volume 3, Issue 10, June-2016 ISSN (Online): 2347 - 4718

Industrial Electronics and Applications.

[6] SibenduSom, Anita I. Ramirez, Douglas E.
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