3D Printed Cellular Structure Materials Under Impact and Compressive Loading

2020 ◽  
Author(s):  
Mahmoud K. Ardebili ◽  
Kerim Tuna Ikikardaslar ◽  
Colt Ehrnfeld ◽  
Feridun Delale
Keyword(s):  
Energy Absorption ◽  
Impact Energy ◽  
Lattice Structure ◽  
Base Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Structure Design ◽  
Impact Testing ◽  
Lateral Direction ◽  
Stacking Order ◽  
3D Printed

Abstract Advances in field of lattice structure design has become possible mainly due to the emerging capabilities of additive manufacturing (AM) or 3D printing. Lattices have the potential to reduce solid volumes, giving advantages such as weight reduction, decreased part production cost and ability to absorb energy under compressive and impact loading. These materials are anisotropic due to structural geometry and the additive nature of 3D-printed layers, which stack mainly in Normal or Lateral direction to the applied load. In this study 3D printed materials were fabricated that are nearly isotropic and are also lighter than base material. The lattice structure was formed using strut-based cell topologies that are adjoined as tetrahedrons. Two different tetrahedron density specimens were produced with Acrylonitrile Butadiene Styrene (ABS) using a Fusion Deposition Modelling (FDM) printer. The fabricated specimens were then tested for impact and compression capabilities. For comparison purposes, solid specimens with the same overall dimensions and highest infill ratio were also produced and tested. After compression and impact testing, results indicated that solid specimens’ impact energy absorption is higher with lateral stacking order relative to load, and compression resistance is higher for normal stacking order. The tetrahedron-filled specimens exhibited minimal stacking directional dependency and the higher count tetrahedron specimens provided more impact energy absorption and more resistance to compression than the lower count one. The normalization of specimens with respect to their weight indicated high density tetrahedron specimens’ impact energy absorption is nearly equal to that of solid specimens’. These results are initial steps in creating lattice structured materials that are isotropic, lighter and stronger than the base material.

Charpy impact energy absorption of 3D printed continuous Kevlar reinforced composites

2021 ◽  
pp. 002199832098559
Author(s):  
Dakota R Hetrick ◽  
Seyed Hamid Reza Sanei ◽  
Omar Ashour ◽  
Charles E Bakis
Keyword(s):  
Energy Absorption ◽  
Impact Energy ◽  
Charpy Impact ◽  
Impact Testing ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
3D Printed ◽  
The Impact

Additive manufacturing (AM) has been used widely to produce three-dimensional (3D) parts from computer-aided design (CAD) software. Traditional Fused Deposition Modeling (FDM) 3D printed polymer parts lack the necessary strength to be used for functional parts in service. The potential of printing continuous fiber reinforced composites has resulted in parts with better mechanical properties and enhanced performance. Very few studies have investigated the impact energy absorption of continuous fiber reinforced 3 D printed composites. The purpose of this work is to investigate the effect of different fiber patterns (unidirectional versus concentric), different stacking patterns (consolidated versus alternating layers), and fiber orientations (0°, 90°, 45°) on the impact energy absorption of 3 D printed continuous Kevlar fiber reinforced Onyx composites. Charpy impact testing was used to determine the impact energy absorption of the specimens. It was concluded that alternating the fiber and matrix layers as opposed to consolidating all the fiber layers in the center of the specimen results in lower impact energy absorption. Additionally, the specimens with unidirectional 90° fiber orientation had the lowest impact energy absorption among the specimens with alternating stacking pattern and those with consolidated [Formula: see text]45° angle-ply fiber orientations had the highest impact energy absorption.

An experimental investigation on mechanical performances of 3D printed lightweight ABS pipes with different cellular wall thickness

2021 ◽  
Vol 15 (2) ◽  
pp. 8169-8177
Author(s):  
Berkay Ergene ◽  
İsmet ŞEKEROĞLU ◽  
Çağın Bolat ◽  
Bekir Yalçın
Keyword(s):  
Compressive Strength ◽  
Energy Absorption ◽  
Wall Thickness ◽  
Lattice Structure ◽  
Honeycomb Structure ◽  
Cellular Structures ◽  
Compression Tests ◽  
Absorbed Energy ◽  
Great Opportunity ◽  
3D Printed

In recent years, cellular structures have attracted great deal of attention of many researchers due to their unique properties like exhibiting high strength at low density and great energy absorption. Also, the applications of cellular structures (or lattice structures) such as wing airfoil, tire, fiber and implant, are mainly used in aerospace, automotive, textile and biomedical industries respectively. In this investigation, the idea of using cellular structures in pipes made of acrylonitrile butadiene styrene (ABS) material was focused on and four different pipe types were designed as honeycomb structure model, straight rib pattern model, hybrid version of the first two models and fully solid model. Subsequently, these models were 3D printed by using FDM method and these lightweight pipes were subjected to compression tests in order to obtain stress-strain curves of these structures. Mechanical properties of lightweight pipes like elasticity modulus, specific modulus, compressive strength, specific compressive strength, absorbed energy and specific absorbed energy were calculated and compared to each other. Moreover, deformation modes were recorded during all compression tests and reported as well. The results showed that pipe models including lattice wall thickness could be preferred for the applications which don’t require too high compressive strength and their specific energy absorption values were notably capable to compete with fully solid pipe structures. In particular, rib shape lattice structure had the highest elongation while the fully solid one possessed worst ductility. Lastly, it is pointed out that 3D printing method provides a great opportunity to have a foresight about production of uncommon parts by prototyping.

3D printed geometrically tessellated sheets with origami-inspired patterns

2021 ◽  
pp. 0021955X2110618
Author(s):  
Anastasia L. Wickeler ◽  
Hani E. Naguib
Keyword(s):  
Impact Energy ◽  
Single Layer ◽  
Impact Testing ◽  
Impact Loads ◽  
Geometrical Complexity ◽  
Impact Forces ◽  
3D Printed ◽  
The Impact ◽  
Multiple Configurations ◽  
Absorb Impact Energy

This study demonstrates that the impact energy absorption capabilities of flexible sheets can be significantly enhanced by implementing tessellated designs into their structure. Configurations of three tessellated geometries were tested; they included a triangular-based, a rectangular-based, and a novel square-based pattern. Due to their geometrical complexity, multiple configurations of these tessellations were printed from a rubber-like material using an inkjet printer with two different thicknesses (2 and 4 mm), and their ability to absorb impact energy was compared to an unpatterned inkjet-printed sheet. In addition, the effect of multi-sheets stacking was also tested. Due to the tailored structure, the impact testing showed that the single-layer sheets were more effective at absorbing impact loads, and experience less deformation, than their two-layer counterparts. The 4 mm thick tessellated patterns were most effective at absorbing impact loads; all three thick patterns measured about 40% lower impact forces transferred to the base of the samples compared to the unpatterned counterparts.

The NSF REU/RET Research on Energy Absorbing 3D Printed Polymer Structures

2017 ◽  
Author(s):  
Benjamin Lewis ◽  
Jonah Leary ◽  
Cynthia Dickman ◽  
Walter Petroski ◽  
Victoria Bellows ◽  
...  
Keyword(s):  
Energy Absorption ◽  
Middle School Teachers ◽  
Undergraduate Students ◽  
Acrylonitrile Butadiene Styrene ◽  
Maximum Load ◽  
Research Experience ◽  
Unit Cells ◽  
3D Printed ◽  
Material Volume ◽  
Energy Absorbing

Energy absorption capability of structures with embedded pores depends upon the amount of voids present and their configurations/distributions. In this study, the energy absorption of acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) structures with varying pore shapes and sizes are investigated. The research was performed by two teams comprised of High School/Middle School teachers and undergraduate students as part of National Science Foundation (NSF) sponsored Research Experience for Teacher (RET)/Research Experience for Undergraduates (REU) teams. ABS samples were fabricated by Team 1 and utilized cubic unit cells with octahedral pores while Team 2 fabricated PLA samples that utilized unit cells with spherical pores. Eight sets of samples with dimensions 25mm × 25mm × 20mm were fabricated using a Makerbot Replicator 2X for ABS samples and a Lulzbot TAZ 5 for PLA samples. Each sample incorporated a 5 × 5 × 4 array of pores. All the samples were tested in compression and energy absorption per unit material volume of all the samples up to a particular maximum load was calculated from load-deflection curves. It is observed that the specific energy absorption of PLA and ABS porous structures greatly increases with increased porosity.

scholarly journals Finite Element Analysis Study on Lattice Structure Fabricated Recycled Polystyrene from Post-used Styrofoam Waste

2021 ◽  
Vol 335 ◽  
pp. 03007
Author(s):  
Chia Zheng Jie Juarez ◽  
Seong Chun Koay ◽  
Ming Yeng Chan ◽  
Hui Leng Choo ◽  
Ming Meng Pang ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Lattice Structure ◽  
Structure Design ◽  
Triangular Prism ◽  
Element Analysis ◽  
Square Prism ◽  
Maximum Stiffness ◽  
3D Printed ◽  
Fea Simulation

Lattice structure design widely applicable for 3D printed components. This research investigated the lattice structure with different shape and relative density using Finite Element Analysis (FEA) simulation. The material used for the lattice structure was the recycled polystyrene made from post-used Styrofoam. The research assessed the mechanical behaviour of lattice structure with either triangular prism and square prism with FEA simulation and numerical mathematical modelling, such as stiffness to-mass ratio, maximum von Misses stress and effective Young’s modulus. The finding FEA shows a good agreement with result from numerical mathematic modelling. The FEA results show lattice structure with triangular prism exhibited lowest value of maximum von Misses stress with maximum stiffness-to-mass value compared to lattice structure square prism. The finding from this work provided an early prediction on mechanical properties of lattice structure fabricated from recycled polystyrene.

scholarly journals An experimental investigation of viscosity of a newly developed natural polymer-based media for abrasive flow machining (AFM) of 3D printed ABS parts

2021 ◽  
Author(s):  
Abdul Wahab Hashmi ◽  
◽  
Harlal Singh Mali ◽  
Anoj Meena ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Base Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Natural Polymer ◽  
Rheological Analysis ◽  
Abrasive Flow Machining ◽  
3D Printed ◽  
Parametric Dependencies ◽  
Waste Polymer

Abrasive Flow Machining (AFM) is the method of finishing complex surfaces and internal channels with the help of extrusion pressure and abrasive-laden viscoelastic polymer media. This paper is based on developing a new AFM media using a natural waste polymer as a base material. In the article, a natural polymer media viz. rice husk ash-based media has been developed, and subsequently, rheological analysis has been done, and experimentation has been performed on Anton-paar® rheometer to optimize the viscosity of these newly developed AFM media. In this research study, the hollow elliptical shape of ABS (acrylonitrile-butadiene-styrene) material was manufactured using the FDM technique and then finished with a one-way AFM machine. This paper examined the parametric dependencies of AFM process parameters on finishing FDM printed hollow elliptical parts. The improved surface roughness of the FDM printed hollow elliptical parts has been investigated relating to the AFM process parameters. The maximum surface roughness has been achieved by 95.98%.

The Influence of Rapid Prototyping Technology on Optimization of Automobile Energy-Absorbing Box

2021 ◽  
Vol 871 ◽  
pp. 153-158
Author(s):  
You Tong Li ◽  
Hui Wang
Keyword(s):  
Rapid Prototyping ◽  
Crystal Lattice ◽  
Energy Absorption ◽  
Impact Energy ◽  
Test Piece ◽  
Lattice Structure ◽  
Compression Modulus ◽  
Energy Absorbing ◽  
The Impact ◽  
Structure Test

To optimize the structure of the automobile energy-absorbing box and obtain the energy-absorbing box structure with improved impact energy absorption property, and apply it to the structure of automobile energy absorption box, test piece of crystal lattice structure and polycrystalline structure of energy-absorbing box are designed via rapid prototyping technology in this study Four different crystal lattice structures of triangle, quadrangle, hexagon, and hollow lattice structure are designed respectively. And their mechanical properties, impact energy absorption properties, and impact properties are tested. The results show that the wall thickness of the four lattices differs greatly when the quality of all crystal lattice structures is 17.8g. The compressive strength and yield strength of the hollow crystal lattice structure test piece are the largest, reaching 51.1Mpa and 69.2Mpa respectively. The maximum compression modulus of the hexagonal lattice test piece is 1462.1, followed by the hollow crystal lattice structure test piece, whose compression modulus value is 1341. The minimum absorption energy of the hollow lattice structure energy-absorbing box test piece is 2847.99J. The minimum impact value of the hollow lattice structure energy-absorbing box test piece is 69.251KN, and the impact value of triangle structure energy-absorbing box test piece is 118.11 KN. The effective impact time of the drop weight test of the hollow lattice structure energy-absorbing box test piece is only 0.08s, the peak value of the impact acceleration is 28.96g, and the maximum load of the test piece is 26.95KN. According to the comprehensive indicators, the hollow lattice structure energy-absorbing box test piece designed based on rapid prototyping technology has improved the impact energy absorption property of the automobile energy-absorbing box.

Quasi-static penetration behavior of fiber-reinforced polypropylene and acrylonitrile butadiene styrene matrix composites

2021 ◽  
pp. 089270572110079
Author(s):  
Ali İmran Ayten
Keyword(s):  
Glass Fiber ◽  
Energy Absorption ◽  
Matrix Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Fiber Types ◽  
Matrix Composites ◽  
Aramid Fabric ◽  
Penetration Behavior ◽  
Fiber Fabric ◽  
Butadiene Styrene

The quasi-static punch shear behaviors of thermoplastic composites with different polymer matrices and fiber types were investigated. This study was also focused on how much energy absorption capability can be increased by low fiber fractions. Maleic anhydride grafted polypropylene (MA-g-PP) and acrylonitrile butadiene styrene (MA-g-ABS) were used as the matrix material. One layer of aramid, carbon and glass fiber plain weave fabrics was used as the reinforcement material. Quasi-static punch shear test (QS-PST) was applied to the samples to understand the penetration behavior of the samples. The damaged areas were investigated and related to force-displacement curves. The results showed that the neat form of MA-g-PP exhibited 158% more energy absorption than the neat form of MA-g-ABS. In the samples containing one layer of fabric, the highest improvement was observed in the aramid fabric-reinforced MA-g-ABS matrix composites. Aramid fabric increased the energy absorption at a rate of 142.3% in comparison to the neat MA-g-ABS, while carbon fiber fabric and glass fiber fabric increased it by 40% and 63.52%, respectively. Aramid fiber fabric provided no significant improvement in the energy absorption in the MA-g-PP matrix composites, while carbon and glass fiber fabrics contributed to energy absorption at a rate of 48% and 41%, respectively.

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