scholarly journals Comparison Of FEA Simulations And Experimental Results For As-Built Additively Manufactured Dogbone Specimens

2021 ◽  
Author(s):  
Prathamesh Baikerikar ◽  
Cameron J Turner
Keyword(s):  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Continuum Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
Accuracy And Precision ◽  
Structure Strength ◽  
Deposition Modeling ◽  
End Use ◽  
Strength And Stiffness

Abstract Parts built using Fused Deposition Modeling (FDM – an additive manufacturing technology) differ from their design model in terms of their microstructure and material properties. These differences lead to a certain amount of ambiguity regarding the structure, strength and stiffness of the final FDM part. Increasing use of FDM parts as end use products, necessitates accurate simulations and analyses during part design. However, analysis methods such as Finite Element Analysis, are used for analysis of continuum models, and may not accurately represent the non-continuous non-linear FDM parts. Therefore, it is necessary to determine the accuracy and precision of FEA for FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. Dogbone geometries that include different infill patterns are tested under tensile loading and later simulated using FEA. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

scholarly journals Comparison of As-Built FEA Simulations and Experimental Results for Additively Manufactured Dogbone Geometries

2017 ◽  
Author(s):  
Prathamesh J. Baikerikar ◽  
Cameron J. Turner
Keyword(s):  
Material Properties ◽  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Tensile Loading ◽  
3D Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
End Use ◽  
Strength And Stiffness

Fused Deposition Modeling (FDM - a technology of additive manufacturing) parts entail a certain amount of ambiguity in terms of its material properties and microstructure due to its manufacturing technique. Therefore, an FDM part differs from its design model in terms of strength and stiffness. With an increasing amount of FDM parts being used as end use products, it is necessary to simulate and analyze them. Due to the differences in microstructure and material properties of FDM parts, it is necessary to determine the accuracy of analysis methods like Finite Element Analysis (FEA) while analyzing the non-continuous, non-linear FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. A dogbone geometry with different infill patterns is tested under tensile loading. Further, as-built 3D models are simulated using FEA and the stress results are compared with experimental data. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

Simulation of edge quality in fused deposition modeling

2019 ◽  
Vol 25 (3) ◽  
pp. 541-554 ◽  
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.

scholarly journals Edge quality in fused deposition modeling: I. Definition and analysis

2017 ◽  
Vol 23 (6) ◽  
pp. 1079-1087 ◽  
Author(s):  
Antonio Armillotta ◽  
Marco Cavallaro
Keyword(s):  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Geometric Errors ◽  
Geometric Accuracy ◽  
Process Map ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Geometric Variables ◽  
Physical Phenomena

Purpose The purpose of this paper is to discuss the problem of the geometric accuracy of edges in parts manufactured by the Fused Deposition Modeling process, as a preliminary step for an experimental investigation. Methodology/approach Three geometric variables (inclination, included and incidence angles) were defined for an edge. The influence of each variable on the geometric errors was explained with reference to specific causes related to physical phenomena and process constraints. Findings Occurrence conditions for all causes were determined and visualized in a process map, which was also developed into a software procedure for the diagnosis of quality issues on digital models of the parts. Research limitations/implications The process map was developed by only empirical considerations and does not allow to predict the amount of geometric errors. In the second part of the paper, experimental tests will help to extend and validate the prediction criteria. Practical implications As demonstrated by an example, the results allow to predict the occurrence of visible defects on the edges of a part before manufacturing it with a given build orientation. Originality/value In literature, the geometric accuracy of additively manufactured parts is only related to surface features. The paper shows that the quality of edges depends on additional variables and causes to be carefully controlled by process choices.

scholarly journals Design of Shoe Soles Using Lattice Structures Fabricated by Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 719-728 ◽  
Author(s):  
Guoying Dong ◽  
Daniel Tessier ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Lattice Structure ◽  
Lattice Structures ◽  
Compression Tests ◽  
Element Analysis ◽  
Fused Deposition ◽  
Footwear Industry ◽  
Deposition Modeling ◽  
Shoe Soles

AbstractAdditive manufacturing (AM) has enabled great application potential in several major industries. The footwear industry can customize shoe soles fabricated by AM. In this paper, lattice structures are discussed. They are used to design functional shoe soles that can have controllable stiffness. Different topologies such as Diamond, Grid, X shape, and Vintiles are used to generate conformal lattice structures that can fit the curved surface of the shoe sole. Finite element analysis is conducted to investigate stress distribution in different designs. The fused deposition modeling process is used to fabricate the designed shoe soles. Finally, compression tests compare the stiffness of shoe soles with different lattice topologies. It is found that the plantar stress is highly influenced by the lattice topology. From preliminary calculations, it has been found that the shoe sole designed with the Diamond topology can reduce the maximum stress on the foot. The Vintiles lattice structure and the X shape lattice structure are stiffer than the Diamond lattice. The Grid lattice structure buckles in the experiment and is not suitable for the design.

scholarly journals The Effects of Combined Infill Patterns on Mechanical Properties in FDM Process

Polymers ◽  
2020 ◽  
Vol 12 (12) ◽  
pp. 2792
Author(s):  
Mohammadreza Lalegani Dezaki ◽  
Mohd Khairol Anuar Mohd Ariffin
Keyword(s):  
Mechanical Properties ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Strength Analysis ◽  
Element Analysis ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed ◽  
Complex Features ◽  
Aided Design

Fused deposition modeling (FDM) is commonly used to print different products with highly complex features. Process parameters for FDM are divided into controllable or uncontrollable parameters. The most critical ones are built orientation, layer thickness, infill pattern, infill density, and nozzle diameter. This study investigates the effects of combined infill patterns in 3D printed products. Five patterns (solid, honeycomb, wiggle, grid, and rectilinear) were combined in samples to analyze their effects on mechanical properties for tensile strength analysis. Polylactic acid (PLA) samples were printed in different build orientations through two directions: flat and on-edge. The limitation was that the software and machine could not combine the infill patterns. Thus, the patterns were designed and assembled in computer aided design (CAD) software. Finite element analysis (FEA) was used to determine the patterns’ features and results showed honeycomb and grid have the highest strength while their weights were lighter compared to solid. Moreover, 0° samples in both flat and on-edge direction had the strongest layer adhesion and the best quality. In contrast, perpendicular samples like 60° and 75° showed poor adhesion and were the weakest specimens in both flat and on-edge, respectively. In brief, by increasing the build orientation, the strength decreases in this study.

Melt Flow Behavior of Polymer Matrix Extrusion for Fused Deposition Modeling (FDM)

2014 ◽  
Vol 660 ◽  
pp. 89-93 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim
Keyword(s):  
Fused Deposition Modeling ◽  
Flow Behavior ◽  
Acrylonitrile Butadiene Styrene ◽  
Extrusion Process ◽  
Melt Flow ◽  
Element Analysis ◽  
Fused Deposition ◽  
Ansys Cfx ◽  
Deposition Modeling ◽  
Higher Temperature

This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene (ABS), High Density Polyethlene (HDPE), Polyproplene (PP) and a combination of ABS-Iron in the extrusion process. In this study, the effect MFB of variety's polymers and ABS mix with 10% Iron material was investigated based on the viscosity, density, thermal conductivity, melting temperature and specific heat material properties. The MFB of FDM system was investigated using Finite-Element Analysis (FEA) by ANSYS CFX 12. Based on the result obtained, it was found that, the material velocity increase when the nozzle diameter is smaller than the entrance diameter. The higher temperature distribution along the MFB of ABS mix with 10% Iron is 43.15 K compared with original ABS, which is 539.15K.

scholarly journals Stress-limiting test structures for rapid low-cost strength and stiffness assessment

2015 ◽  
Vol 21 (2) ◽  
pp. 144-151 ◽  
Author(s):  
Andrew Katz ◽  
Justin Nussbaum ◽  
Craig P Lusk ◽  
Nathan B Crane
Keyword(s):  
Fused Deposition Modeling ◽  
Low Cost ◽  
Test Methods ◽  
Measurement Sensitivity ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Strength And Stiffness ◽  
Accuracy And Repeatability ◽  
Printing Parameters

Purpose – The purpose of this paper is to evaluate the use of a simple printed geometry to estimate mechanical properties (elastic modulus, yield strength) with inexpensive test equipment. Design/methodology/approach – Test geometry is presented that enables controlled strains with manual deformation and repeatable measurement of vibrational frequencies. This is tested with multiple fused deposition modeling (FDM) machines to assess measurement accuracy and repeatability. Printing orientation and some printing parameters are varied to assess the measurement sensitivity. Findings – The test methods show good correlation with manufacturer material specifications in the X-Y plane and reported elastic strain limits. It is also sensitive to printing orientation and printing parameters. Research limitations/implications – Further work is needed to assess the sensitivity of the method to particular defects and parameter errors expected in particular applications. Originality/value – This method supports process monitoring in production environments and inexpensive assessments of material properties for hobbyist and do-i- yourself users. While it is tested with FDM, it should be applicable to other additive manufacturing processes.

scholarly journals Optimization of Vibration Characteristics of Fused Deposition Modeling Color 3D Printer Based on Modal and Power Spectrum Method

2019 ◽  
Vol 9 (19) ◽  
pp. 4154 ◽  
Author(s):  
Dawei Zhang ◽  
Zhiyong Li ◽  
Shengxue Qin ◽  
Shanling Han
Keyword(s):  
Finite Element ◽  
Power Spectrum ◽  
Fused Deposition Modeling ◽  
Vibration Signal ◽  
Frequency Domain Analysis ◽  
Vibration Characteristics ◽  
3D Printer ◽  
Element Analysis ◽  
Fused Deposition ◽  
Deposition Modeling

To improve the accuracy of the Fused Deposition Modeling (FDM) color 3D printer in printing color pieces, the vibration characteristics were studied. Firstly, the models of the FDM color 3D printer were qualitatively simplified by mechanics theory to provide theoretical support for dynamic characteristics of the structure, and the finite element modal analysis was performed by the ANSYS (It is an engineering simulation and 3D design software) Workbench to obtain the natural frequency and mode shape displacement of the FDM color 3D printer. Then, the power spectrum of the vibration signal of the previous FDM color 3D printer was measured through frequency domain analysis, and the resonance positions of the 3D printer were obtained by comparing the finite element analysis with experimental analysis. Finally, the design of the color 3D printer was optimized based on the analysis. The results indicate that the optimized scheme can effectively improve the resonance characteristics of the device and reduce the overall modal displacement. The actual experiment of the 3D printer demonstrates that the accuracy of the optimized device has been improved, which has crucial reference significance for the development of the FDM color 3D printer.

Switchable Bistability in 3D Printed Shells With Bio-Inspired Architectures and Spatially Distributed Pre-Stress

2018 ◽  
Author(s):  
Karl Jin Ang ◽  
Katherine S. Riley ◽  
Jakob Faber ◽  
Andres F. Arrieta
Keyword(s):  
3D Printing ◽  
Room Temperature ◽  
Fused Deposition Modeling ◽  
Element Analysis ◽  
Fused Deposition ◽  
Spatially Distributed ◽  
Deposition Modeling ◽  
3D Printed ◽  
And Control ◽  
Careful Design

Using fused deposition modeling (FDM) 3D printing, we combine a bio-inspired bilayer architecture with distributed pre-stress and the shape memory behavior of polylactic acid (PLA) to manufacture shells with switchable bistability. These shells are stiff and monostable at room temperature, but become elastic and bistable with fast morphing when heated above their glass transition temperature. When cooled back down, the shells retain the configuration they were in at the elevated temperature and return to being stiff and monostable. These programmed deformations result from the careful design and control of how the filament is extruded by the printer and therefore, the resulting directional pre-stress. Parameter studies are presented on how to maximize the pre-stress for this application. The shells are analyzed using nonlinear finite element analysis. By leveraging the vast array of geometries accessible with 3D printing, this method can be extended to complex, multi-domain shells, including bio-inspired designs.

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