Characterization of effective Young’s modulus for Fused Deposition Modeling manufactured topology optimization designs

In this work, an innovative green composite was produced by adding Hedysarum coronarium (HC) flour to a starch-based biodegradable polymer (Mater-Bi®, MB). The flour was obtained by grinding together stems, leaves and flowers and subsequently sieving it, selecting a fraction from 75 μm to 300 μm. Four formulations have been produced by compression molding (CM) and fused deposition modeling (FDM) by adding 5%, 10%, 15% and 20% of HC to MB. The influence of filler content on the processability was tested, and rheological, morphological and mechanical properties of composites were also assessed. Through CM, it was possible to obtain easily homogeneous samples with all filler amounts. Concerning FDM, 5% and 10% HC-filled composites proved also easily printable. Mechanical results showed filler effectively acted as reinforcement: Young’s modulus and tensile strengths of the composites increased from 74.3 MPa to 236 MPa and from 18.6 MPa to 33.4 MPa, respectively, when 20% of HC was added to the pure matrix. FDM samples, moreover, showed higher mechanical properties if compared with CM ones due to rectilinear infill and fibers orientation. In fact, regarding the 10% HC composites, Young’s modulus of the CM and FDM ones displayed a relative increment of 176% and 224%, respectively.

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Characterization of Mechanical Property of PLA-ABS Functionally Graded Material Fabricated by Fused Deposition Modeling

10.1115/gtindia2021-76025 ◽

2021 ◽

Author(s):

Ziyi Su ◽

Kazuaki Inaba ◽

Amit Karmakar ◽

Apurba Das

Keyword(s):

Tensile Test ◽

Young’S Modulus ◽

Natural Frequency ◽

Functionally Graded Material ◽

Fused Deposition Modeling ◽

Young's Modulus ◽

Functionally Graded ◽

Fused Deposition ◽

Graded Material ◽

Deposition Modeling

Abstract Application of functionally graded materials (FGMs) in energy, aviation and nuclear industries has increased since the last decade due to potential reduction of in-plane and transverse through-the-thickness stresses, enhanced residual stress distribution, superior thermal properties, free from delamination, and reduced stress intensity factors. FGMs are categorized as an advanced class of composite materials where the two constituent materials are graded along the thickness direction. Absence of sharp change in material property in the interface layer eliminates the problem of delamination and debonding, which is a major concern for traditional composite material. In this work, PLA-ABS functionally graded material is manufactured using additive manufacturing techniques through fused deposition modeling (FDM) using Y-type extruder. X-ray computed tomography test is conducted to see the air void (generated during printing) distribution in the printed FGM. Tensile test (as per ISO-527standrad) is conducted to evaluate the Young’s Modulus of additive manufactured FGMs. Three different measuring positions are considered in the FGM specimens to check the effect of property change along the grading direction. Tensile test results of PLA-ABS FGM are compared with their individual constituents (ABS and PLA). Further, flexural vibration test is conducted to evaluate the natural frequency of printed FGM beam. Experimentally determined mechanical and dynamic characteristics in terms effective Young’s Modulus and natural frequency are analyzed and discussed.

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Optimization of fused deposition modeling process parameters using the Taguchi method to improve the tensile properties of 3D-printed polyether ether ketone

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211017572 ◽

2021 ◽

pp. 146442072110175

Author(s):

Timoumi Mohamed ◽

Najoua Barhoumi ◽

Khalid Lamnawar ◽

Abderrahim Maazouz ◽

Amna Znaidi

Keyword(s):

Tensile Properties ◽

Young’S Modulus ◽

Layer Thickness ◽

Process Parameters ◽

Fused Deposition Modeling ◽

Young's Modulus ◽

Fused Deposition ◽

Polyether Ether Ketone ◽

Deposition Modeling ◽

Ether Ketone

The interesting mechanical properties of polyether ether ketone give the material a place among the foremost competitors when it comes to replacing metal. Fused deposition modeling has been recognized as an alternative method to process polyether ether ketone parts. In this study, the effect of different process parameters such as nozzle, bed, and radiant temperatures as well as printing speed and layer thickness on the tensile properties of three-dimensional printed polyether ether ketone was investigated. The optimization of the tensile properties of PEEK were studied by performing a reduced number of experiments, using the experimental design method based on the Taguchi approach which limits the number of experiments to 8 instead of 32. Results showed that a decent Young’s modulus was found by setting the nozzle temperature, print speed, and bed temperatures to their high levels and by setting the layer thickness and radiant temperature to their low level. Using these parameters, a Young’s modulus of 3.5 GPa was obtained, which represents 87.5% of the value indicated in the technical sheet. With these settings, we also found a tensile strength of 45.5 MPa, which corresponds to 46.4% of the value given by the studied polyether ether ketone material. A scanning electron microscopic investigation of the porosity and interlayer adhesion, confirmed that a higher bed temperature also tended to promote adhesion between layers.

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A Comparative Analysis of Selected Methods for Determining Young’s Modulus in Polylactic Acid Samples Manufactured with the FDM Method

Materials ◽

10.3390/ma15010149 ◽

2021 ◽

Vol 15 (1) ◽

pp. 149

Author(s):

Bartosz Pszczółkowski ◽

Konrad W. Nowak ◽

Wojciech Rejmer ◽

Mirosław Bramowicz ◽

Łukasz Dzadz ◽

...

Keyword(s):

Young’S Modulus ◽

Polylactic Acid ◽

Fused Deposition Modeling ◽

Young's Modulus ◽

Acrylonitrile Butadiene Styrene ◽

Tensile Tests ◽

Fused Filament Fabrication ◽

Fused Deposition ◽

Static Tensile ◽

Deposition Modeling

The objective of this study was to compare three methods for determining the Young’s modulus of polylactic acid (PLA) and acrylonitrile-butadiene-styrene (ABS) samples. The samples were manufactured viathe fused filament fabrication/fused deposition modeling (FFF/FDM) 3D printing technique. Samples for analysis were obtained at processing temperatures of 180 °C to 230 °C. Measurements were performed with the use of two nondestructive techniques: the impulse excitation technique (IET) and the ultrasonic (US) method. The results were compared with values obtained in static tensile tests (STT), which ranged from 2.06 ± 0.03 to 2.15 ± 0.05 GPa. Similar changes in Young’s modulus were observed in response to the processing temperatures of the compared methods. The values generated by the US method were closer to the results of the STT, but still diverged considerably, and the error exceeded 10% in all cases. Based on the present findings, it might be concluded that the results of destructive and nondestructive tests differ by approximately 1 GPa.

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DENSITY BASED TOPOLOGY OPTIMIZATION FOR FUSED DEPOSITION MODELING ON MECHANICAL APDL

10.26678/abcm.cobem2019.cob2019-1921 ◽

2019 ◽

Author(s):

Lucas Inácio ◽

Dianne Magalhães Viana

Keyword(s):

Topology Optimization ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Deposition Modeling

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Design and Characterization of a Screw Extrusion Hot-End for Fused Deposition Modeling

Molecules ◽

10.3390/molecules26030590 ◽

2021 ◽

Vol 26 (3) ◽

pp. 590

Author(s):

Tim Feuerbach ◽

Markus Thommes

Keyword(s):

Vinyl Acetate ◽

Fused Deposition Modeling ◽

Ethylene Vinyl Acetate ◽

Direct Printing ◽

Fused Deposition ◽

Screw Extrusion ◽

Deposition Modeling ◽

Feedstock Material ◽

Material Form

The filament is the most widespread feedstock material form used for fused deposition modeling printers. Filaments must be manufactured with tight dimensional tolerances, both to be processable in the hot-end and to obtain printed objects of high quality. The ability to successfully feed the filament into the printer is also related to the mechanical properties of the filament, which are often insufficient for pharmaceutically relevant excipients. In the scope of this work, an 8 mm single screw hot-end was designed and characterized, which allows direct printing of materials from their powder form and does not require an intermediate filament. The capability of the hot-end to increase the range of applicable excipients to fused deposition modeling was demonstrated by processing and printing several excipients that are not suitable for fused deposition modeling in their filament forms, such as ethylene vinyl acetate and poly(1-vinylpyrrolidone-co-vinyl acetate). The conveying characteristic of the screw was investigated experimentally with all materials and was in agreement with an established model from literature. The complete design information, such as the screw geometry and the hot-end dimensions, is provided in this work.

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Automated Testing and Characterization of Additive Manufacturing (ATCAM)

Journal of Materials Engineering and Performance ◽

10.1007/s11665-021-06042-2 ◽

2021 ◽

Author(s):

Arash Alex Mazhari ◽

Randall Ticknor ◽

Sean Swei ◽

Stanley Krzesniak ◽

Mircea Teodorescu

Keyword(s):

Additive Manufacturing ◽

Fused Deposition Modeling ◽

Cell System ◽

Automated Testing ◽

Fused Deposition ◽

Deposition Modeling ◽

Machine Calibration

AbstractThe sensitivity of additive manufacturing (AM) to the variability of feedstock quality, machine calibration, and accuracy drives the need for frequent characterization of fabricated objects for a robust material process. The constant testing is fiscally and logistically intensive, often requiring coupons that are manufactured and tested in independent facilities. As a step toward integrating testing and characterization into the AM process while reducing cost, we propose the automated testing and characterization of AM (ATCAM). ATCAM is configured for fused deposition modeling (FDM) and introduces the concept of dynamic coupons to generate large quantities of basic AM samples. An in situ actuator is printed on the build surface to deploy coupons through impact, which is sensed by a load cell system utilizing machine learning (ML) to correlate AM data. We test ATCAM’s ability to distinguish the quality of three PLA feedstock at differing price points by generating and comparing 3000 dynamic coupons in 10 repetitions of 100 coupon cycles per material. ATCAM correlated the quality of each feedstock and visualized fatigue of in situ actuators over each testing cycle. Three ML algorithms were then compared, with Gradient Boost regression demonstrating a 71% correlation of dynamic coupons to their parent feedstock and provided confidence for the quality of AM data ATCAM generates.

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Simulation of edge quality in fused deposition modeling

Rapid Prototyping Journal ◽

10.1108/rpj-06-2018-0151 ◽

2019 ◽

Vol 25 (3) ◽

pp. 541-554 ◽

Cited By ~ 2

Author(s):

Antonio Armillotta

Keyword(s):

Fused Deposition Modeling ◽

Experimental Tests ◽

Geometric Errors ◽

Content Type ◽

Fused Deposition ◽

Graphical Simulation ◽

Deposition Modeling ◽

Edge Quality ◽

Input Variables

Purpose The purpose of this paper is to propose a method for simulating the profile of part edges as a result of the FDM process. Deviations from nominal edge shape are predicted as a function of the layer thickness and three characteristic angles depending on part geometry and build orientation. Design/methodology/approach Typical patterns of edge profiles were observed on sample FDM parts and interpreted as the effects of possible toolpath generation strategies. An algorithm was developed to generate edge profiles consistent with the patterns expected for any combination of input variables. Findings Experimental tests confirmed that the simulation procedure can correctly predict basic geometric properties of edge profiles such as frequency, amplitude and shape of periodic asperities. Research limitations/implications The algorithm takes into account only a subset of the error causes recognized in previous studies. Additional causes could be integrated in the simulation to improve the estimation of geometric errors. Practical implications Edge simulation may help avoid process choices that result in aesthetic and functional defects on FDM parts. Originality/value Compared to the statistical estimation of geometric errors, graphical simulation allows a more detailed characterization of edge quality and a better diagnosis of error causes.

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