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.

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.

Investigation of Moisture Sensitivity Related Failure Mechanism of Quad Flat No-Lead (QFN) Packages

2008 ◽  
Author(s):  
Minshu Zhang ◽  
S. W. Ricky Lee
Keyword(s):  
Finite Element ◽  
Failure Mechanism ◽  
Material Properties ◽  
Test Performance ◽  
Interfacial Adhesion ◽  
Failure Modes ◽  
Material Selection ◽  
Mechanical Tests ◽  
Element Analysis ◽  
Moisture Sensitivity

Interfacial delamination is a long existing problem in the moisture preconditioning process and reflow. The failure is caused by the competition between interfacial strength and hygrothermal stress. Many simulations based on the finite element model have been applied to study the failure mechanism of this phenomenon. However, the difficulty in obtaining material properties of mini-size packages, the lack of experiment investigation of interfacial adhesion and the less-understood moisture analysis will always bring many challenges to simulations. To avoid the above issues, dummy QFN packages were fabricated as the test vehicle for the investigation of the moisture related failure. The major advantage of using dummy packages is that all material properties could be traced and all geometric parameters could be determined without ambiguities. With everything under control, failure modes could be generated within expectation. This would provide a good experiment comparison for future finite element analysis. In this study, several experiment procedures were implemented to establish the relationship between material selection and moisture sensitivity level (MSL) test performance. They were package fabrication, mechanical tests for interfacial adhesion, C-SAM and cross-section inspections. Based on the experimental results, features of the moisture related failure mechanism are presented in this paper.

Finite Element Analysis on the Failure Behavior of Straight Pipe With Wall Thinning

2004 ◽  
Author(s):  
Ken Inoue ◽  
Koji Takahashi ◽  
Kotoji Ando ◽  
Seok Hwan Ahn ◽  
Ki Woo Nam ◽  
...  
Keyword(s):  
Finite Element ◽  
Failure Modes ◽  
Local Buckling ◽  
Metal Loss ◽  
Failure Behavior ◽  
Straight Pipe ◽  
Element Analysis ◽  
Deformation And Failure ◽  
Wall Thinning ◽  
Local Wall Thinning

Monotonic four-point bending tests were conducted using straight pipe specimens 102 mm in diameter with local wall thinning in order to investigate the effects of the depth, shape, and location of wall thinning on the deformation and failure behavior of pipes. The local wall thinning simulated erosion/corrosion metal loss. The deformation and fracture behavior of the straight pipes with local wall thinning was compared with that of non wall-thinning pipes. The failure modes were classified as local buckling, ovalization, or crack initiation depending on the depth, shape, and location of the local wall thinning. Three-dimensional elasto-plastic analyses were carried out using the finite element method. The deformation and failure behavior, simulated by finite element analyses, coincided with the experimental results.

Evaluation of Mechanical Reliability of Micro Bump in Semiconductors Through a Shear Test

2021 ◽  
Author(s):  
Y. J. Cho ◽  
M. B. Han ◽  
J. S. Bae ◽  
I. J. Choi ◽  
D. S. Choi ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Shear Strength ◽  
Robust Design ◽  
Shear Test ◽  
Failure Modes ◽  
Element Model ◽  
Mechanical Tests ◽  
Mechanical Reliability ◽  
Element Analysis

Abstract Micro bump in semiconductor devices is an element to connect silicon dies with through-silicon via to be stacked on each other. The failure of these micro bumps is directly related to the reliability of semiconductors. Of the various mechanical tests, a shear test is commonly used to evaluate mechanical reliability because it provides relatively simple and reliable evaluation data. This paper investigated the failure modes of micro bump due to the structure of micro bumps and tip speed through finite element analysis and shear test. A shear test was conducted for four structures of micro bumps with the radius of 25 μm using a Dage4000+ bond tester under two tip speeds. A finite element model representing the shear test was developed by ANSYS and the analysis was conducted under the same conditions as the experiment. It shows that tungsten via are effective in increasing shear strength of micro bump. Moreover, it also proposes a robust design to increase shear strength of a micro bump.

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

2021 ◽  
pp. 146442072110071
Author(s):  
AIL Pais ◽  
C Silva ◽  
MC Marques ◽  
JL Alves ◽  
J Belinha
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Meshless Method ◽  
Load Case ◽  
Fused Filament Fabrication ◽  
Ductile Metals ◽  
Four Point Bending ◽  
Bending Load

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.

scholarly journals Design and analysis of concrete-filled tubular flange girders under combined loading

2021 ◽  
pp. 136943322110015
Author(s):  
Rana Al-Dujele ◽  
Katherine Ann Cashell
Keyword(s):  
Finite Element ◽  
Axial Force ◽  
Failure Modes ◽  
Numerical Study ◽  
Combined Loading ◽  
Torsional Stiffness ◽  
Fe Model ◽  
Combined Effects ◽  
Element Analysis ◽  
Hollow Section

This paper is concerned with the behaviour of concrete-filled tubular flange girders (CFTFGs) under the combination of bending and tensile axial force. CFTFG is a relatively new structural solution comprising a steel beam in which the compression flange plate is replaced with a concrete-filled hollow section to create an efficient and effective load-carrying solution. These members have very high torsional stiffness and lateral torsional buckling strength in comparison with conventional steel I-girders of similar depth, width and steel weight and are there-fore capable of carrying very heavy loads over long spans. Current design codes do not explicitly include guidance for the design of these members, which are asymmetric in nature under the combined effects of tension and bending. The current paper presents a numerical study into the behaviour of CFTFGs under the combined effects of positive bending and axial tension. The study includes different loading combinations and the associated failure modes are identified and discussed. To facilitate this study, a finite element (FE) model is developed using the ABAQUS software which is capable of capturing both the geometric and material nonlinearities of the behaviour. Based on the results of finite element analysis, the moment–axial force interaction relationship is presented and a simplified equation is proposed for the design of CFTFGs under combined bending and tensile axial force.

Failure Analysis of Bamboo Bolt Connection in Uniaxial Tension by FEM by Considering Fiber Direction

2021 ◽  
Vol 71 (1) ◽  
pp. 58-64
Author(s):  
Raviduth Ramful
Keyword(s):  
Finite Element ◽  
Uniaxial Tension ◽  
Failure Modes ◽  
Damage Mechanism ◽  
Field Analysis ◽  
Fiber Direction ◽  
Element Formulation ◽  
Element Analysis ◽  
Test Standards ◽  
Lack Of Information

Abstract Full-culm bamboo has been used for millennia in construction. Specific connections are normally required to suit its unique morphology and nonuniform structure. Presently, the use of full-culm bamboo is limited in the construction industry as a result of a lack of information and test standards about the use and evaluation of full-culm connections. This study aims to further explore this area by investigating the failure modes in bamboo bolt connections in uniaxial tension by considering fiber direction in finite element analysis. Three types of bolt configurations of varying permutations, namely, single, dual, and orthogonal, were investigated. An orthotropic material was used as a constitutive model in finite element formulation to capture the inhomogeneity prevailing in bamboo culm. From the strain-field analysis of a hollow-inhomogeneous model representing bamboo, shear-out failure was dominant, as a localized area equivalent to the bolt diameter was affected due to high material orthotropy with high axial strength but weak radial and tangential strength. Bearing failure is assumed to precede shear-out failure at the bolt–bamboo contact interface, as the embedding strength was affected by localized strain concentration. The strain distribution in various bolt arrangements was found to vary between bolted connections of inhomogeneous-hollow geometry of bamboo and the ones of inhomogeneous-solid geometry representing timber. The observation in this study highlights the need for alternative design criteria to specifically assess the damage mechanism in bamboo connections.

TTK Chitra tilting disc heart valve model TC2: An assessment of fatigue life and durability

2017 ◽  
Vol 231 (8) ◽  
pp. 758-765 ◽  
Author(s):  
NN Subhash ◽  
Adathala Rajeev ◽  
Sreedharan Sujesh ◽  
CV Muraleedharan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Heart Valve ◽  
Life Prediction ◽  
Heart Valves ◽  
Failure Modes ◽  
Fatigue Life Prediction ◽  
Element Analysis ◽  
Valve Model

Average age group of heart valve replacement in India and most of the Third World countries is below 30 years. Hence, the valve for such patients need to be designed to have a service life of 50 years or more which corresponds to 2000 million cycles of operation. The purpose of this study was to assess the structural performance of the TTK Chitra tilting disc heart valve model TC2 and thereby address its durability. The TC2 model tilting disc heart valves were assessed to evaluate the risks connected with potential structural failure modes. To be more specific, the studies covered the finite element analysis–based fatigue life prediction and accelerated durability testing of the tilting disc heart valves for nine different valve sizes. First, finite element analysis–based fatigue life prediction showed that all nine valve sizes were in the infinite life region. Second, accelerated durability test showed that all nine valve sizes remained functional for 400 million cycles under experimental conditions. The study ensures the continued function of TC2 model tilting disc heart valves over duration in excess of 50 years. The results imply that the TC2 model valve designs are structurally safe, reliable and durable.

Material Flow Rate Estimation in Material Extrusion Additive Manufacturing

2021 ◽  
Vol 13 (1) ◽  
pp. 46-56
Author(s):  
G.P. Greeff
Keyword(s):  
Additive Manufacturing ◽  
Flow Rate ◽  
Material Flow ◽  
Fused Deposition Modeling ◽  
Volumetric Flow Rate ◽  
Cost Effective ◽  
Fused Filament Fabrication ◽  
Material Extrusion ◽  
Fused Deposition ◽  
G Code

The additive manufacturing of products promises exciting possibilities. Measurement methodologies, which measure an in-process dataset of these products and interpret the results, are essential. However, before developing such a level of quality assurance several in-process measurands must be realized. One of these is the material flow rate, or rate of adding material during the additive manufacturing process. Yet, measuring this rate directly in material extrusion additive manufacturing presents challenges. This work presents two indirect methods to estimate the volumetric flow rate at the liquefier exit in material extrusion, specifically in Fused Deposition Modeling or Fused Filament Fabrication. The methods are cost effective and may be applied in future sensor integration. The first method is an optical filament feed rate and width measurement and the second is based on the liquefier pressure. Both are used to indirectly estimate the volumetric flow rate. The work also includes a description of linking the G-code command to the final print result, which may be used to create a per extrusion command model of the part.

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