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.

scholarly journals Load Distribution on PET-G 3D Prints of Honeycomb Cellular Structures under Compression Load

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1983
Author(s):  
Olimpia Basurto-Vázquez ◽  
Elvia P. Sánchez-Rodríguez ◽  
Graham J. McShane ◽  
Dora I. Medina
Keyword(s):  
Fused Deposition Modeling ◽  
Structural Characteristics ◽  
Honeycomb Structure ◽  
Cellular Structures ◽  
Displacement Curve ◽  
Compression Tests ◽  
Compression Load ◽  
Fused Deposition ◽  
3D Printed ◽  
Printing Direction

Energy resulting from an impact is manifested through unwanted damage to objects or persons. New materials made of cellular structures have enhanced energy absorption (EA) capabilities. The hexagonal honeycomb is widely known for its space-filling capacity, structural stability, and high EA potential. Additive manufacturing (AM) technologies have been effectively useful in a vast range of applications. The evolution of these technologies has been studied continuously, with a focus on improving the mechanical and structural characteristics of three-dimensional (3D)-printed models to create complex quality parts that satisfy design and mechanical requirements. In this study, 3D honeycomb structures of novel material polyethylene terephthalate glycol (PET-G) were fabricated by the fused deposition modeling (FDM) method with different infill density values (30%, 70%, and 100%) and printing orientations (edge, flat, and upright). The effectiveness for EA of the design and the effect of the process parameters of infill density and layer printing orientation were investigated by performing in-plane compression tests, and the set of parameters that produced superior results for better EA was determined by analyzing the area under the curve and the welding between the filament layers in the printed object via FDM. The results showed that the printing parameters implemented in this study considerably affected the mechanical properties of the 3D-printed PET-G honeycomb structure. The structure with the upright printing direction and 100% infill density exhibited an extension to delamination and fragmentation, thus, a desirable performance with a long plateau region in the load–displacement curve and major absorption of energy.

scholarly journals Effect of Absorbent Foam Filling on Mechanical Behaviors of 3D-Printed Honeycombs

Polymers ◽  
2020 ◽  
Vol 12 (9) ◽  
pp. 2059
Author(s):  
Leilei Yan ◽  
Keyu Zhu ◽  
Yunwei Zhang ◽  
Chun Zhang ◽  
Xitao Zheng
Keyword(s):  
Compressive Strength ◽  
Elastic Modulus ◽  
Energy Absorption ◽  
Unit Volume ◽  
Honeycomb Structure ◽  
Unit Mass ◽  
Out Of Plane ◽  
Foam Filling ◽  
3D Printed ◽  
Foam Filled

Polylactic acid (PLA) hexagonal honeycomb structures were fabricated by using 3D-printing technology. By filling with absorbent polymethacrylimide (PMI) foam, a novel absorbent-foam-filled 3D-printed honeycomb was obtained. The in-plane (L- and W-direction) and out-of-plane (T-direction) compressive performances were studied experimentally and numerically. Due to absorbent PMI foam filling, the elastic modulus, compressive strength, energy absorption per unit volume, and energy absorption per unit mass of absorbent-foam-filled honeycomb under L-direction were increased by 296.34%, 168.75%, 505.57%, and 244.22%, respectively. Moreover, the elastic modulus, compressive strength, energy absorption per unit volume, and energy absorption per unit mass, under W-direction, also have increments of 211.65%, 179.85, 799.45%, and 413.02%, respectively. However, for out-of-plane compression, the compressive strength and energy absorption per unit volume were enhanced, but the density has also been increased; thus, it is not competitive in energy absorption per unit mass. Failure mechanism and dimension effects of absorbent-foam-filled honeycomb were also considered. The approach of absorbent foam filling made the 3D-printed honeycomb structure more competitive in electromagnetic wave stealth applications, while acting simultaneously as load-carrying structures.

Compressive Stress of Syntactic Foam: Effect of rNBR Particles Reinforced Epoxy Macrospheres (rNBR-EM)

2018 ◽  
Vol 280 ◽  
pp. 301-307
Author(s):  
Z. Zakaria ◽  
C.Y. Yao
Keyword(s):  
Compressive Strength ◽  
Physical Properties ◽  
Compressive Stress ◽  
Energy Absorption ◽  
Wall Thickness ◽  
Syntactic Foam ◽  
Radius Ratio ◽  
Butadiene Rubber ◽  
Syntactic Foams ◽  
Compressive Properties

This research focuses on the effect of rejected nitrile butadiene rubber (rNBR) gloves particles reinforced epoxy macrospheres (EM) on the physical properties and compressive stress of syntactic foam. Adding rNBR particles on the surface of macrospheres can increase the energy absorption as a result of improving the compressive properties of syntactic foam. Three types of macrospheres have been produced for the fabrication of syntactic foam, namely EM without rNBR, 1-layer rNBR-EM and 2-layer rNBR-EM. The results showed that increased rNBR particles layer on macrospheres has increased the wall thickness, and reduced the radius ratio of macrospheres as well as increased the density of syntactic foams. The compressive strength and modulus of syntactic foam with 2-rNBR-EM increased compared to the syntactic foams of 1-rNBR-EM and EM without rNBR. In addition, the toughness of the 2-rNBR-EM increased compared to the syntactic foams of 1-rNBR-EM and EM without rNBR.

Design of Honeycomb Mesostructures for Crushing Energy Absorption

2012 ◽  
Vol 134 (7) ◽  
Author(s):  
Jesse Schultz ◽  
David Griese ◽  
Jaehyung Ju ◽  
Prabhu Shankar ◽  
Joshua D. Summers ◽  
...  
Keyword(s):  
Sensitivity Analysis ◽  
Energy Absorption ◽  
Wall Thickness ◽  
High Speed ◽  
Fe Simulation ◽  
Honeycomb Structure ◽  
Maximum Energy ◽  
Geometric Parameters ◽  
Constant Mass ◽  
Absorption Properties

This paper presents the energy absorption properties of hexagonal honeycomb structures of varying cellular geometries under high speed in-plane crushing. While the crushing responses in terms of energy absorption and densification strains have been extensively researched and reported, a gap is identified in the generalization of honeycombs with contr’olled and varying geometric parameters. This paper addresses this gap through a series of finite element (FE) simulations where the cell angle and the inclined wall thickness, are varied while maintaining a constant mass of the honeycomb structure. A randomly filled, nonrepeating design of experiments (DOEs) is generated to determine the effects of these geometric parameters on the output of energy absorbed and a statistical sensitivity analysis is used to determine the parameters significant for the crushing energy absorption of honeycombs. It is found that while an increase in the inclined wall thickness enhances the energy absorption of the structure, increases in either the cell angle or ratio of cell angle to inclined wall thickness have adverse effects on the output. Finally, the optimization results suggest that a cellular geometry with a positive cell angle and a high inclined wall thickness provides for maximum energy absorption, which is verified with a 6% error when compared to a FE simulation.

On the Crushing Behavior of Foam-Filled Composite Tubes under Compressive Loading

2012 ◽  
Vol 626 ◽  
pp. 1038-1041 ◽  
Author(s):  
Akbar Othman ◽  
Shahrum Abdullah ◽  
Ahmad Kamal Ariffin ◽  
Nik Abdullah Nik Mohamed ◽  
Helmi Rashid
Keyword(s):  
Energy Absorption ◽  
Wall Thickness ◽  
Peak Load ◽  
Compressive Loading ◽  
Absorbed Energy ◽  
Polymeric Foam ◽  
Foam Filled ◽  
Marine Applications ◽  
Crushing Behavior ◽  
Initial Peak

The present papers determine the effect of composite pultrusion square tubes E-glass polyester empty and polymeric foam-filled subjected to axial compressive loading. The specimens of square composite pultrusion were compressed experimentally under axial loadings to examine the effect of empty and polymeric foam-filled with different wall-thickness. The wall-thickness was used in this study were 2.1 and 2.4 mm. During the experimental observation, three characteristic crushing stages were identified as initial peak load, progressive crushing and compaction zone stages. The composite pultrusion square tube profile were analyzed and investigated in terms of crashworthiness parameters to meet the improvement of structural material widely used in automobile, aerospace and marine applications. Result obtained from experimental analysis such that initial peak load, mean load, energy absorption and specific energy absorption versus displacement curves were compared for each specimen. Results showed that the tubes energy absorption was affected significantly by different tube profile. It is also found that the polymeric foam-filled exhibit superb crashworthy structure on specific absorbed energy and the amount of initial peak load, mean load and absorbed energy recorded higher than the empty tube profiles.

Fabrication and Properties of Syntactic Magnesium Foams

1998 ◽  
Vol 521 ◽  
Author(s):  
M. Hartmann ◽  
K. Reindel ◽  
R. F. Singer
Keyword(s):  
Compressive Strength ◽  
Energy Absorption ◽  
Wall Thickness ◽  
Volume Fraction ◽  
Hollow Spheres ◽  
Three Dimensional ◽  
Syntactic Foam ◽  
Absorption Efficiency ◽  
Casting Technique ◽  
Energy Absorption Efficiency

ABSTRACTSyntactic magnesium foams which consist of thin-walled hollow alumina spheres embedded in a magnesium matrix were fabricated by infiltrating a three-dimensional array of hollow spheres with a magnesium melt by using a gas pressure-assisted casting technique.The resulting composite contains closed cells of homogeneous and isotropic morphology. The densities of the syntactic magnesium foams were between 1.0 and 1.4 g/cm3. The densities were controlled by variations in the bulk density of the hollow spheres with the volume fraction of spheres kept constant at approximately 63 %.Compressive deformation characteristics of the composites were evaluated with respect to the influence of matrix strength and sphere wall thickness on characteristic variables such as compressive strength, plateau stress and energy absorption efficiency. Differences in the strength of the magnesium-based matrix materials investigated (cp-Mg, AM20, AM50, AZ91) had little influence on the compressive strength of the syntactic foam. However, an increasing relative wall thickness of the hollow ceramic spheres led to a significant strength enhancement. In all cases the ratio between compressive and plateau strength rose with increasing composite strength resulting in decreasing energy absorption efficiency.

Optimal Sinusoidal Cellular Structures for Energy Absorption

2016 ◽  
Author(s):  
Yunyao Jiang ◽  
Yaning Li
Keyword(s):  
Finite Element ◽  
Energy Absorption ◽  
Maximum Energy ◽  
Deformation Mechanisms ◽  
Analytical Models ◽  
Cellular Structures ◽  
Material Models ◽  
Linear Elastic ◽  
Cyclic Compression ◽  
3D Printed

In this investigation, the elastic mechanical properties of the sinusoidal cellular structures were first explored via analytical models. The analytical analysis showed that for linear elastic materials, the amplitude-to-wavelength ratio of the sinusoidal structures is a key geometric parameter to determine the deformation mechanisms. To further evaluate the influences of the geometric nonlinearity, a set of finite element simulations were performed for sinusoidal structures with the same density but various amplitude-to-wavelength ratios. It was found that the optimal amplitude-to-wavelength ratio for the maximum energy absorption corresponds to the transition between symmetric to asymmetric deformation mechanisms. Selected designs were fabricated via a 3D printer (Objet, Connex 260). Mechanical experiments under quasi-static uniaxial compression and cyclic compression were performed on the 3D printed specimens. Finite element (FE) simulations with both linear elastic and nonlinear hyperelastic material models were performed and compared with the experiments. The 3D-printed sinusoidal structures were shown to be re-configurable under cyclic loading.

ENERGY ABSORPTION EFFICIENCY IN CELLULAR SOLIDS

2008 ◽  
Vol 22 (09n11) ◽  
pp. 1730-1735 ◽  
Author(s):  
KUNIHARU USHIJIMA ◽  
DAI-HENG CHEN ◽  
HIRONOBU NISITANI
Keyword(s):  
Energy Absorption ◽  
Honeycomb Structure ◽  
Absorption Efficiency ◽  
Absorption Capacity ◽  
Cellular Solids ◽  
Absorbed Energy ◽  
Energy Absorption Capacity ◽  
Geometrical Properties ◽  
Energy Absorption Efficiency ◽  
New Type

In this paper, a new type of honeycomb structure is proposed to enhance the energy absorption capacity for a honeycomb structure, and investigated its energy absorption efficiency (absorbed energy per unit volume) by finite element method (FEM). This model has small arc-shaped parts on the double cell wall, and can be manufactured by a similar way of standard honeycomb structures. Also, the proposed structure has large rigidity of plastic bending without increasing the mass. In this paper, effects of geometrical properties on the energy absorption characteristics are discussed.

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