Tools for Makers (e.g. *.qalc for VSCode Qalc)

maker.qalc

#------------------------------------------------------------------------------- constants

    # Dichte
    rho_PLA = 1240 kg/m^3 # Dichte von PLA
    rho_PETG = 1250 kg/m^3  # Dichte von PETG
    eta_PLA = 1000 Pa s

    filament_d = 1.75 mm
    nozzle_d = 0.8 mm

#------------------------------------------------------------------------------- printer constants

    rotation_distance_H2 = 4 mm

#------------------------------------------------------------------------------- general

    area(d) = pi * (d / 2)^2
    v_from_flow(flow, area) = flow/area in mm/s
    ve_from_filament_flow(flow) = v_from_flow(flow, area(filament_d))
    v_from_flow_rect(flow, width, height) = v_from_flow(flow, width*height)

    kg_per_N = kg/N
    mg_per_N = mg/N

#------------------------------------------------------------------------------- speed vs. flow etc.

    rpm_from_flow(flow, rotation_distance) = flow/rotation_distance/area(filament_d)
    rpm_from_flow_H2(flow) = rpm_from_flow(flow, rotation_distance_H2)

  #--------------------------------------------------------------------- extrude

    flow = 15 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

    flow = 20 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

    flow = 25 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

    flow = 30 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

    flow = 45 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

    flow = 70 mm^3/s
    rpm_from_flow_H2(flow)
    ve_from_filament_flow(flow)

  #--------------------------------------------------------------------- 0.8/0.25

    width = 0.8 mm
    height = 0.25 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

  #--------------------------------------------------------------------- 0.8/0.4

    width = 0.8 mm
    height = 0.4 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

  #--------------------------------------------------------------------- 1.0/0.2

    width = 1.0 mm
    height = 0.2 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

  #--------------------------------------------------------------------- 1.0/0.25

    width = 1.0 mm
    height = 0.25 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

  #--------------------------------------------------------------------- 1.0/0.3

    width = 1.0 mm
    height = 0.3 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

  #--------------------------------------------------------------------- 1.0/0.5

    width = 1.0 mm
    height = 0.5 mm

    flow = 15 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 20 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 25 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 30 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 45 mm^3/s ; v_from_flow_rect(flow, width, height)
    flow = 70 mm^3/s ; v_from_flow_rect(flow, width, height)

#------------------------------------------------------------------------------- belt tension vs. resonance frequency

    f_reso_belt(len, weight, density) = 1/(2*len) * sqrt((weight * 9.81 m/s^2)/density)

    dens_gates = 0.0083 kg/m in g/m

    # black, cheap china belt (quite stiff, no steel inlet)
    dens_black_meas = 37 g / 3.93 m
    # brown, cheap china belt (thin, flexible)
    dens_brown_meas = 7 g / 1.06 m

  #----- user hg

    len_hg_y = 550 mm
    len_hg_x = 330 mm

    f_reso_belt(len_hg_y, 6 lb, dens_gates)
    f_reso_belt(len_hg_x, 6 lb, dens_gates)

    f_reso_belt(len_hg_y, 5 lb, dens_brown_meas)
    f_reso_belt(len_hg_x, 5 lb, dens_brown_meas)

    f_reso_belt(len_hg_y, 5 lb, dens_black_meas)

  #----- user sk

    len_sk_y = 400 mm
    len_sk_x = 330 mm

    f_reso_belt(len_sk_y, 6 lb, dens_gates)
    f_reso_belt(len_sk_x, 6 lb, dens_gates)

    f_reso_belt(len_sk_y, 8 lb, dens_gates)
    f_reso_belt(len_sk_x, 8 lb, dens_gates)

#------------------------------------------------------------------------------- force by narrowing of nozzle area
    # results are suspicious

    # Bernoulli equation to calculate delta P
        # eta: dynamic viscosity of the filament (Pa.s, is not used here)
        # rho: density of filaments (kg/m^3)
        # d_in: diameter of the entrance opening (m)
        # d_out: diameter of the exit opening (m)
        # v_in: speed on entry (m/s)
    F_narrowing(rho, d_in, d_out, v_in) = area(d_in) * rho * ((v_in * area(d_in)/area(d_out))^2 / 2 - v_in^2 / 2)

    #nozzle_d = 0.6 mm
    nozzle_d = 1.0 mm
    d_in = 2 mm
    d_out = nozzle_d
    v_in = ve_from_filament_flow(25 mm^3/s) in mm/s

    # example calculation
    A_in = area(d_in)
    A_out = area(d_out)
    v_out = A_in*v_in/A_out in mm/s
    delta_p = ((rho_PLA*v_in^2)/2 - (rho_PLA*v_out^2)/2) in Pa
    F_PLA = delta_p * A_in / gravity in mg

    F_narrowing_PLA = F_narrowing(rho_PLA, d_in, d_out, v_in) / gravity in mg
    F_narrowing_PETG = F_narrowing(rho_PETG, d_in, d_out, v_in) / gravity in mg

    flow = 25 mm^3/s
    nozzle_l = 1mm
    F_flow(flow, len, d, eta) = (8 * eta * len * flow) / (d/2)^2

    F_flow(flow, nozzle_l, nozzle_d, eta_PLA) in N
    F_flow(flow, nozzle_l, nozzle_d, eta_PLA) / gravity in g


#------------------------------------------------------------------------------- etc

  # very fast printing
  v_from_flow_rect(60mm^3/s, 0.4mm, 0.1mm)