The influence of infill density gradient on the mechanical properties of PLA optimized structures by additive manufacturing

Author(s):  
AIL Pais ◽  
C Silva ◽  
MC Marques ◽  
JL Alves ◽  
J Belinha

The aim of this work is the development of a novel framework for structural optimization using bio-inspired remodelling algorithm adapted to additive manufacturing. The fact that polylactic acid (PLA, E = 3145 MPa (Young’s modulus) according to the supplier for parts obtained by injection) shows a similar parameterized behavior with ductile metals, in the sense that both materials are characterized by a bi-linear elastic-plastic law, allows to simulate and prototype parts to be further constructed in ductile metals at a lower cost and then be produced with more expensive fabrication processes. Moreover, cellular materials allow for a significant weight reduction and therefore reduction of production costs. Structural optimization algorithms based on biological phenomena were used to determine the density distribution of the infill density of the specimens. Several simple structures were submitted to distinct complex load cases and analyzed using the mentioned optimization algorithms combined with the finite element method and a meshless method. The surface was divided according to similar density and then converted to stereolitography files and infilled with the gyroid structure at the desired density determined before, using open-source slicing software. Smoothing functions were used to smooth the density field obtained with the remodeling algorithms. The samples were printed with fused filament fabrication technology and submitted to mechanical flexural tests similar to the ones analyzed analytically, namely three- and four-point bending tests. Thus, the factors of analysis were the smoothing parameter and the remodeling method, and the responses evaluated were stiffness, specific stiffness, maximum force, and mass. The experimental results correlated (obtaining accuracy of 35% for the three-point bending load case and 5% for the four-point bending load case) to the numerical results in terms of flexural stiffness and it was found that the complexity of the load case is relevant for the efficiency of the functional gradient. The fused filament fabrication process is still not accurate enough to be able to experimentally compare the results based of finite element method and meshless method analyses.

2006 ◽  
Vol 321-323 ◽  
pp. 1495-1498 ◽  
Author(s):  
Dong Hyung Lee ◽  
Seok Jin Kwon ◽  
Chan Woo Lee ◽  
Jae Boong Choi ◽  
Young Jin Kim

In this paper the fretting wear of press-fitted specimens under partial slip conditions was simulated using finite element method and numerical analysis based on Archard's equation. An elasto-plastic analysis of contact stresses in a press-fitted shaft in contact with a boss was conducted with finite element method and the amount of microslip and contact pressure due to bending load was estimated. The predicted wear profile of press-fitted specimens at the contact edge was compared with the experimental results. It is found that the depth of fretting wear by repeated slip between shaft and boss reaches the maximum value at the contact edge. The initial surface profile is continuously changed by the wear at the contact edge, and then the corresponding contact stresses and strain are redistributed.


Polymers ◽  
2020 ◽  
Vol 12 (4) ◽  
pp. 965 ◽  
Author(s):  
Benjamin Kromoser ◽  
Thomas Pachner

Free-formed frameworks are architecturally appealing constructions. They allow for maximum creative freedom as well as for a structural optimization of the support structure. The design and construction of these kind of structures is complex however, and therefore challenging, with each frame member having an individual length, each cladding plate an individual dimension and especially each knot having an individual geometry. The result is that geometry optimization and production technology become the most important processes when striving for an economic and ecological construction. The goals of the authors are the automation of the design process by applying a parametric model and the collection of the complete complexity in the knots as well as the production of these knots without material wastage by additive manufacturing. The development process was split into three different phases: (1) Preliminary experiments determining the tension, compression and bending load-bearing behavior of the knots produced by additive manufacturing, using different polymer-based materials: ABS, ASA, PA-CF, PA6CT, PCX, PETG and a mixture of PLA and ABS. (2) Development of an automated digital workflow for the design and production of these structures by the use of a parametric approach. (3) Design, production and assembly of a full-scale prototype in the form of a free-formed shell structure spanning an area of 20 m2. The prototype was made from fumed oak wood members in combination with white stained plywood panels connected by knots produced by Fused Filament Fabrication (FFF) additive manufacturing, using polymer-based materials and screws. At the end of the contribution, a summary and an outlook on further research is given.


Author(s):  
Yonghong Zhang ◽  
Zhenfei Zhao ◽  
Yaqing Zhang ◽  
Wenjie Ge

Abstract In order to prevent mesh distortion problem arising in topology optimization of compliant mechanism with massive displacement, a meshless Galerkin method was proposed and studied in this paper. The element-free Galerkin method (EFG) is more accurate than the finite element method, and it does not need grids. However, it is difficult to impose complex boundaries. This paper presents a topology optimization method based on interpolation meshless method, which retains the advantages of the finite element method (FEM) that is easy to impose boundary conditions and high accuracy of the meshless method. At the same time, a method of gradually reducing step is proposed to solve the problem of non-linear convergence caused by low-density points in topology optimization. Numerical example shows that these techniques are valid in topology optimization of compliant mechanism considering the geometric nonlinearity, and simultaneously these techniques can also improve the convergence of nonlinearity.


Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1740 ◽  
Author(s):  
Sebastian Marian Zaharia ◽  
Larisa Anamaria Enescu ◽  
Mihai Alin Pop

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.


2014 ◽  
Vol 611-612 ◽  
pp. 811-817 ◽  
Author(s):  
Julen Ibabe ◽  
Antero Jokinen ◽  
Jari Larkiola ◽  
Gurutze Arruabarrena

Additive Manufacturing technology offers almost unlimited capacity when manufacturing parts with complex geometries which could be impossible to get with conventional manufacturing processes. This paper is based on the study of a particular real part which has been redesigned and manufactured using an AM process. The challenge consists of redesigning the geometry of an originally aluminium made part, in order to get a new stainless steel made model with same mechanical properties but with less weight. The new design is the result of a structural optimization process based on Finite Element simulations which is carried out bearing in mind the facilities that an AM process offers.


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