
Improving the combined DEM-discrete fresh concrete approach for modeling 3D concrete printing
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Three-dimensional concrete printing (3DCP) has gained attention in recent years as a promising technique in civil engineering, offering several benefits over traditional construction methods. However, there are still challenges in improving the manufacturing process, such as the rheological behavior of fresh concrete, layer thickness of the printed filaments, printer path, and nozzle geometry. In this work, we integrate the Discrete Fresh Concrete (DFC) model into into an in-house formulation of the Discrete Element Method (DEM) to simulate the flow characteristics of fresh printable concrete during deposition. By performing controlled simulations of single-layer straight-line printing, we systematically explore the effect of printing speed and mixture properties on filament stability. Our results evidence a critical speed threshold for a given concrete mixture: at slower speeds (4–8 cm/s), the deposited material forms coherent and stable layers, while at higher speeds, it not only forms uneven layers but also breaks due to inertial forces. A deficiency of the original DFC model is found in both particle-surface and particle-particle interactions, where tangential velocities do not dissipate completely and stabilize at non-zero values, as static friction is not accounted for. To overcome this issue, we suggest modifying the model by introducing tangential stiffness terms and incorporating static friction and rolling resistance to better capture particle adhesion and energy dissipation. We show that this approach, with the proposed adjustments, can be an effective tool for enhancing the predicitive capabiliteis of 3DCP process simulations.