Purpose - This paper presents a first step toward developing a comprehensivemethodology for fully resolved numerical simulations of fusion depositionmodeling. Design/methodology/approach - A front-tracking/finite volume methodpreviously developed for simulations of multiphase flows is extended to modelthe injection of hot polymer and its cooling down. Findings - The accuracy andconvergence properties of the new method are tested by grid refinement and themethod is shown to produce convergent solutions for the shape of the filament,the temperature distribution, contact area and reheat region when new filamentsare deposited on top of previously laid down filaments. Researchlimitations/implications - The present paper focuses on modeling the fluid flowand the cooling. The modeling of solidification, volume changes and residualstresses will be described in Part II. Practical implications - The ability tocarry our fully resolved numerical simulations of the fusion deposition processis expected to help explore new deposition strategies and to provide the"ground truth" for the development of reduced order models. Originality/value -The present paper is the first fully resolved simulation of the deposition infusion filament modeling.
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