Effects of infill patterns on the strength and stiffness of 3D printed topologically optimized geometries

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nadim S. Hmeidat ◽  
Bailey Brown ◽  
Xiu Jia ◽  
Natasha Vermaak ◽  
Brett Compton
Keyword(s):  
Material Properties ◽  
Failure Modes ◽  
Mechanical Anisotropy ◽  
Failure Behavior ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Orthotropic Composite ◽  
Material Extrusion ◽  
Specific Material ◽  
Strength And Stiffness

Purpose Mechanical anisotropy associated with material extrusion additive manufacturing (AM) complicates the design of complex structures. This study aims to focus on investigating the effects of design choices offered by material extrusion AM – namely, the choice of infill pattern – on the structural performance and optimality of a given optimized topology. Elucidation of these effects provides evidence that using design tools that incorporate anisotropic behavior is necessary for designing truly optimal structures for manufacturing via AM. Design/methodology/approach A benchmark topology optimization (TO) problem was solved for compliance minimization of a thick beam in three-point bending and the resulting geometry was printed using fused filament fabrication. The optimized geometry was printed using a variety of infill patterns and the strength, stiffness and failure behavior were analyzed and compared. The bending tests were accompanied by corresponding elastic finite element analyzes (FEA) in ABAQUS. The FEA used the material properties obtained during tensile and shear testing to define orthotropic composite plies and simulate individual printed layers in the physical specimens. Findings Experiments showed that stiffness varied by as much as 22% and failure load varied by as much as 426% between structures printed with different infill patterns. The observed failure modes were also highly dependent on infill patterns with failure propagating along with printed interfaces for all infill patterns that were consistent between layers. Elastic FEA using orthotropic composite plies was found to accurately predict the stiffness of printed structures, but a simple maximum stress failure criterion was not sufficient to predict strength. Despite this, FE stress contours proved beneficial in identifying the locations of failure in printed structures. Originality/value This study quantifies the effects of infill patterns in printed structures using a classic TO geometry. The results presented to establish a benchmark that can be used to guide the development of emerging manufacturing-oriented TO protocols that incorporate directionally-dependent, process-specific material properties.

scholarly journals Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing

Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1740 ◽  
Author(s):  
Sebastian Marian Zaharia ◽  
Larisa Anamaria Enescu ◽  
Mihai Alin Pop
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Failure Modes ◽  
Sandwich Structures ◽  
Leading Edge ◽  
Mechanical Tests ◽  
Failure Behavior ◽  
Fused Filament Fabrication ◽  
Element Analysis ◽  
Material Extrusion

Material Extrusion-Based Additive Manufacturing Process (ME-AMP) via Fused Filament Fabrication (FFF) offers a higher geometric flexibility than conventional technologies to fabricate thermoplastic lightweight sandwich structures. This study used polylactic acid/polyhydroxyalkanoate (PLA/PHA) biodegradable material and a 3D printer to manufacture lightweight sandwich structures with honeycomb, diamond-celled and corrugated core shapes as a single part. In this paper, compression, three-point bending and tensile tests were performed to evaluate the performance of lightweight sandwich structures with different core topologies. In addition, the main failure modes of the sandwich structures subjected to mechanical tests were evaluated. The main failure modes that were observed from mechanical tests of the sandwich structure were the following: face yielding, face wrinkling, core/skin debonding. Elasto-plastic finite element analysis allowed predicting the global behavior of the structure and stressing distribution in the elements of lightweight sandwich structures. The comparison between the results of bending experiments and finite element analyses indicated acceptable similarity in terms of failure behavior and force reactions. Finally, the three honeycomb, diamond-celled and corrugated core typologies were used in the leading edge of the wing and were impact tested and the results created favorable premises for using such structures on aircraft models and helicopter blade structures.

Fuzzy risk assessment for electro-optical target tracker

2016 ◽  
Vol 33 (6) ◽  
pp. 830-851 ◽  
Author(s):  
Soumen Kumar Roy ◽  
A K Sarkar ◽  
Biswajit Mahanty
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Linear Equations ◽  
Mode Analysis ◽  
Failure Behavior ◽  
Membership Functions ◽  
Design And Development ◽  
Effect Analysis ◽  
Content Type ◽  
Criticality Analysis

Purpose – The purpose of this paper is to evolve a guideline for scientists and development engineers to the failure behavior of electro-optical target tracker system (EOTTS) using fuzzy methodology leading to success of short-range homing guided missile (SRHGM) in which this critical subsystems is exploited. Design/methodology/approach – Technology index (TI) and fuzzy failure mode effect analysis (FMEA) are used to build an integrated framework to facilitate the system technology assessment and failure modes. Failure mode analysis is carried out for the system using data gathered from technical experts involved in design and realization of the EOTTS. In order to circumvent the limitations of the traditional failure mode effects and criticality analysis (FMECA), fuzzy FMCEA is adopted for the prioritization of the risks. FMEA parameters – severity, occurrence and detection are fuzzifed with suitable membership functions. These membership functions are used to define failure modes. Open source linear programming solver is used to solve linear equations. Findings – It is found that EOTTS has the highest TI among the major technologies used in the SRHGM. Fuzzy risk priority numbers (FRPN) for all important failure modes of the EOTTS are calculated and the failure modes are ranked to arrive at important monitoring points during design and development of the weapon system. Originality/value – This paper integrates the use of TI, fuzzy logic and experts’ database with FMEA toward assisting the scientists and engineers while conducting failure mode and effect analysis to prioritize failures toward taking corrective measure during the design and development of EOTTS.

Predicting strength of additively manufactured thermoplastic polymer parts produced using material extrusion

2018 ◽  
Vol 24 (2) ◽  
pp. 321-332 ◽  
Author(s):  
Joseph Bartolai ◽  
Timothy W. Simpson ◽  
Renxuan Xie
Keyword(s):  
Infrared Imaging ◽  
Acrylonitrile Butadiene Styrene ◽  
Temperature History ◽  
Interface Temperature ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Material Extrusion ◽  
Rheological Data ◽  
History Of ◽  
Butadiene Styrene

Purpose The weakest point in additively manufactured polymer parts produced by material extrusion additive manufacturing (MEAM) is the interface between adjacent layers and deposition toolpaths or “roads”. This study aims to predict the mechanical strength of parts by utilizing a novel analytical approach. Strength predictions are made using the temperature history of these interfaces, polymer rheological data, and polymer weld theory. Design/methodology/approach The approach is validated using experimental data for two common 3D-printed polymers: polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). Interface temperature history data are collected in situ using infrared imaging. Rheological data of the polycarbonate and acrylonitrile butadiene styrene used to fabricate the fused filament fabrication parts in this study have been determined experimentally. Findings The strength of the interfaces has been predicted, to within 10% of experimental strength, using polymer weld theory from the literature adapted to the specific properties of the polycarbonate and acrylonitrile butadiene styrene feedstock used in this study. Originality/value This paper introduces a novel approach for predicting the strength of parts produced by MEAM based on the strength of interfaces using polymer weld theory, polymer rheology, temperature history of the interface and the forces applied to the interface. Unlike methods that require experimental strength data as a prediction input, the proposed approach is material and build orientation agnostic once fundamental parameters related to material composition have been determined.

Additive manufacturing of 316L stainless-steel structures using fused filament fabrication technology: mechanical and geometric properties

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Miguel Ángel Caminero ◽  
Ana Romero ◽  
Jesús Miguel Chacón ◽  
Pedro José Núñez ◽  
Eustaquio García-Plaza ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Austenitic Stainless Steel ◽  
Material Properties ◽  
Steel Structures ◽  
Fused Filament Fabrication ◽  
Geometric Properties ◽  
Content Type ◽  
Build Orientation ◽  
Manufacturing Alternatives

Purpose Fused filament fabrication (FFF) technique using metal filled filaments in combination with debinding and sintering steps can be a cost-effective alternative for laser-based powder bed fusion processes. The mechanical behaviour of FFF-metal materials is highly dependent on the processing parameters, filament quality and adjusted post-processing steps. In addition, the microstructural material properties and geometric characteristics are inherent to the manufacturing process. The purpose of this study is to characterize the mechanical and geometric performance of three-dimensional (3-D) printed FFF 316 L metal components manufactured by a low-cost desktop 3-D printer. The debinding and sintering processes are carried out using the BASF catalytic debinding process in combination with the BASF 316LX Ultrafuse filament. Special attention is paid on the effects of build orientation and printing strategy of the FFF-based technology on the tensile and geometric performance of the 3-D printed 316 L metal specimens. Design/methodology/approach This study uses a toolset of experimental analysis techniques [metallography and scanning electron microcope (SEM)] to characterize the effect of microstructure and defects on the material properties under tensile testing. Shrinkage and the resulting porosity of the 3-D printed 316 L stainless steel sintered samples are also analysed. The deformation behaviour is investigated for three different build orientations. The tensile test curves are further correlated with the damage surface using SEM images and metallographic sections to present grain deformation during the loading progress. Mechanical properties are directly compared to other works in the field and similar additive manufacturing (AM) and Metal Injection Moulding (MIM) manufacturing alternatives from the literature. Findings It has been shown that the effect of build orientation was of particular significance on the mechanical and geometric performance of FFF-metal 3-D printed samples. In particular, Flat and On-edge samples showed an average increase in tensile performance of 21.7% for the tensile strength, 65.1% for the tensile stiffness and 118.3% for maximum elongation at fracture compared to the Upright samples. Furthermore, it has been able to manufacture near-dense 316 L austenitic stainless steel components using FFF. These properties are comparable to those obtained by other metal conventional processes such as MIM process. Originality/value 316L austenitic stainless steel components using FFF technology with a porosity lower than 2% were successfully manufactured. The presented study provides more information regarding the dependence of the mechanical, microstructural and geometric properties of FFF 316 L components on the build orientation and printing strategy.

Response of Resin Transfer Molded (RTM) Composites Under Reversed Cyclic Loading

1996 ◽  
Vol 118 (1) ◽  
pp. 49-57 ◽  
Author(s):  
Hassan Mahfuz ◽  
Anwar Haque ◽  
Daixu Yu ◽  
Shaik Jeelani
Keyword(s):  
Failure Modes ◽  
Load Level ◽  
Failure Behavior ◽  
Progressive Damage ◽  
Damage Growth ◽  
Static Tests ◽  
Strength And Stiffness ◽  
Reversed Cyclic ◽  
Fatigue Failures ◽  
Circular Notch

Compressive behavior and the tension-compression fatigue response of resin transfer molded IM7 PW/PR 500 composite laminate with a circular notch have been studied. Fatigue damage characteristics have been investigated through the changes in the laminate strength and stiffness by gradually incrementing the fatigue cycles at a preselected load level. Progressive damage in the surface of the laminate during fatigue has been investigated using cellulose replicas. Failure mechanisms during static and cyclic tests have been identified and presented in detail. Extensive debonding of filaments and complete fiber bundle fracture accompanied by delamination were found to be responsible for fatigue failures, while fiber buckling, partial fiber fracture and delamination were characterized as the failure modes during static tests. Weibull analysis of the static, cyclic and residual tests have been performed and described in detail. Fractured as well as untested specimens were C-scanned, and the progressive damage growth during fatigue is presented. Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) for the fractured specimen were also performed and the analysis of the failure behavior is presented.

High Speed Fracture Phenomena in Dyneema Composite

2007 ◽  
Vol 353-358 ◽  
pp. 120-125 ◽  
Author(s):  
Beate D. Heru Utomo ◽  
B.J. van der Meer ◽  
L.J. Ernst ◽  
D.J. Rixen
Keyword(s):  
Material Properties ◽  
Cohesive Zone ◽  
High Speed ◽  
Material Model ◽  
Protection Level ◽  
Projectile Impact ◽  
New Material ◽  
Specific Material ◽  
Strength And Stiffness ◽  
Impact Experiments

Dyneema composite is used in lightweight armour applications, because of its high specific material properties such as strength and stiffness. In armour applications, Dyneema composite is used to protect people or vehicles from projectile impact. In order to be able to guarantee a certain protection level, an accurate prediction of fracture phenomena that are caused by projectile impact is required. Currently, fracture phenomena such as delamination and fibre fracture are not accurately described. This is because a good understanding of fracture phenomena in Dyneema composite lacks. Therefore, both Dyneema fibre and Dyneema composite are analysed by different (impact) experiments to gain more insight in both the fracture phenomena as well as in the material properties. Parallel to these experiments, a start is made with the development of a new material model in ABAQUS\Explicit using cohesive zone techniques that is able to predict the fracture phenomena due to projectile impact.

scholarly journals Fatigue Resistance and Failure Behavior of Penetration and Non-Penetration Laser Welded Lap Joints

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Xiangzhong Guo ◽  
Wei Liu ◽  
Xiqing Li ◽  
Haowen Shi ◽  
Zhikun Song
Keyword(s):  
Fatigue Resistance ◽  
Failure Modes ◽  
Plate Thickness ◽  
High Stress ◽  
Lap Joints ◽  
Failure Behavior ◽  
Passenger Cars ◽  
Plate Fracture ◽  
The Difference ◽  
Railway Passenger

AbstractPenetration and non-penetration lap laser welding is the joining method for assembling side facade panels of railway passenger cars, while their fatigue performances and the difference between them are not completely understood. In this study, the fatigue resistance and failure behavior of penetration 1.5+0.8-P and non-penetration 0.8+1.5-N laser welded lap joints prepared with 0.8 mm and 1.5 mm cold-rolled 301L plates were investigated. The weld beads showed a solidification microstructure of primary ferrite with good thermal cracking resistance, and their hardness was lower than that of the plates. The 1.5+0.8-P joint exhibited better fatigue resistance to low stress amplitudes, whereas the 0.8+1.5-N joint showed greater resistance to high stress amplitudes. The failure modes of 0.8+1.5-N and 1.5+0.8-P joints were 1.5 mm and 0.8 mm lower lap plate fracture, respectively, and the primary cracks were initiated at welding fusion lines on the lap surface. There were long plastic ribs on the penetration plate fracture, but not on the non-penetration plate fracture. The fatigue resistance stresses in the crack initiation area of the penetration and non-penetration plates calculated based on the mean fatigue limits are 408 MPa and 326 MPa, respectively, which can be used as reference stress for the fatigue design of the laser welded structures. The main reason for the difference in fatigue performance between the two laser welded joints was that the asymmetrical heating in the non-penetration plate thickness resulted in higher residual stress near the welding fusion line.

scholarly journals Analytical Investigation of Tension Loaded Deformed Rebar Anchors in Concrete

CivilEng ◽  
2021 ◽  
Vol 2 (2) ◽  
pp. 442-458
Author(s):  
Sandip Chhetri ◽  
Rachel A. Chicchi
Keyword(s):  
Test Data ◽  
Parametric Study ◽  
Failure Modes ◽  
Experimental Testing ◽  
Analytical Investigation ◽  
Failure Behavior ◽  
Capacity Design ◽  
Simulation Results

Experimental testing of deformed rebar anchors (DRAs) has not been performed extensively, so there is limited test data to understand their failure behavior. This study aims to expand upon these limited tests and understand the behavior of these anchors, when loaded in tension. Analytical benchmark models were created using available test data and a parametric study of deformed rebar anchors was performed. Anchor diameter, spacing, embedment, and number of anchors were varied for a total of 49 concrete breakout simulations. The different failure modes of anchors were predicted analytically, which showed that concrete breakout failure is prominent in the DRA groups. The predicted concrete breakout values were consistent with mean and 5% fractile concrete capacities determined from the ACI concrete capacity design (CCD) method. The 5% fractile factor determined empirically from the simulation results was kc = 26. This value corresponds closely with kc = 24 specified in ACI 318-19 and ACI 349-13 for cast-in place anchors. The analysis results show that the ACI CCD formula can be conservatively used to design DRAs loaded in tension by applying a kc factor no greater than 26.

scholarly journals Evaluation of the influence of design in the mechanical properties of honeycomb cores used in composite panels

2021 ◽  
pp. 146442072098519
Author(s):  
A Miranda ◽  
M Leite ◽  
L Reis ◽  
E Copin ◽  
MF Vaz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Polylactic Acid ◽  
Failure Modes ◽  
Industrial Applications ◽  
Sandwich Composite ◽  
Composite Panels ◽  
Distribution Analysis ◽  
Absorbed Energy ◽  
Fused Filament Fabrication ◽  
Subtractive Manufacturing

The aerospace, automotive, and marine industries are heavily reliant on sandwich panels with cellular material cores. Although honeycombs with hexagonal cells are the most commonly used geometries as cores, recently there have been new alternatives in the design of lightweight structures. The present work aims to evaluate the mechanical properties of metallic and polymeric honeycomb structures, with configurations recently proposed and different in-plane orientations, produced by additive and subtractive manufacturing processes. Structures with configurations such as regular hexagonal honeycomb (Hr), lotus (Lt), and hexagonal honeycomb with Plateau borders (Pt), with 0°, 45°, and 90° orientations were analyzed. To evaluate its properties, three-point bending tests were performed, both experimentally and by numerical modeling, by means of the finite element method. Honeycombs of two aluminum alloys and polylactic acid were fabricated. The structures produced in aluminum were obtained either by selective laser melting technology or by machining, while polylactic acid structures were obtained by material extrusion using fused filament fabrication. From the stress distribution analysis and the load–displacement curves, it was possible to evaluate the strength, stiffness, and absorbed energy of the structures. Failure modes were also analyzed for polylactic acid honeycombs. In general, a strong correlation was observed between numerical and experimental results. The results show that the stiffness and absorbed energy increase in the order, Hr, Pt, Lt, and with the orientation through the sequence, 45°, 90°, 0°. Thus, Lt structures with 0° orientation seem to be good alternatives to the traditional honeycombs used in sandwich composite panels for those industrial applications where low weight, high stiffness, and large energy-absorbing capacity are required.

Numerical analysis of damage zones in a bridge

2019 ◽  
Vol 11 (1) ◽  
pp. 1-12
Author(s):  
Mohammed Lamine Moussaoui ◽  
Mohamed Chabaat
Keyword(s):  
Numerical Analysis ◽  
Material Properties ◽  
Data File ◽  
Time Range ◽  
Bridge Structure ◽  
Time Step ◽  
Batch Mode ◽  
Content Type ◽  
Finite Element Software ◽  
Von Mises

Purpose The purpose of this paper is to present a numerical analysis of structural monitoring for damage zones detection. The study is performed with Ansys finite element software, which reads in batch mode programming a previously generated mesh data file and computes the transient dynamic solution for each time-step iteration within an analysis time range. Design/methodology/approach The approach itself is applied on a bridge structure which can be potentially subjected to damage zones due to severe loads cases and or earthquakes vibrations. The ideal Von Mises failure criterion ellipsoid envelope is applied for the detection of overstepped computed stresses and strains. Findings This numerical analysis allows computing, for each time-step iteration, the dynamic displacements at each degree of freedom and the corresponding stresses and strains inside the elements under the action of several times dependent loads cases. Practical implications Several simulations are considered to quantify the external loads. Originality/value The material properties of reinforced concrete RC are calculated for an existing specific bridge structure case. The RC strength is then introduced from the basic compounds material properties using the corresponding volumes fractions.

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