Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density
The optimum selection of process parameters, materials, and product design is essential to achieve the desired response of 3D-printed structures, especially in functional components. The current practices of the experimental optimization process require significant resources, which can be limited th...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-03-01
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| Series: | Results in Engineering |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123022005308 |
| _version_ | 1797961224879603712 |
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| author | Ans Al Rashid Muammer Koç |
| author_facet | Ans Al Rashid Muammer Koç |
| author_sort | Ans Al Rashid |
| collection | DOAJ |
| description | The optimum selection of process parameters, materials, and product design is essential to achieve the desired response of 3D-printed structures, especially in functional components. The current practices of the experimental optimization process require significant resources, which can be limited through numerical modeling and simulation techniques. In this study, a thermomechanical numerical model is used to predict the performance of the additive manufacturing (AM) process, i.e., fused filament fabrication (FFF). 3D printing (3DP) process simulations were performed for tensile testing coupons using carbon fiber-reinforced polyamide-6 (PA6-CF) material. The numerical model predicted the effect of infill patterns and densities on the deflections and distortions during the FFF process. The numerical model predictions were validated via experiments performed under similar conditions. The results conclude that the numerical model can adequately predict the process-induced deflections and distortions during the FFF process. Generally, higher dimensional control was observed for rectangular infill patterns and increased infill density. However, the numerical model overestimates the shrinkage as the stress-relaxation effect is not considered in the numerical model and underestimates the warpages as perfect build plate adhesion is assumed. |
| first_indexed | 2024-04-11T00:55:44Z |
| format | Article |
| id | doaj.art-ac2c791530f143a4b6a911e2acc533de |
| institution | Directory Open Access Journal |
| issn | 2590-1230 |
| language | English |
| last_indexed | 2024-04-11T00:55:44Z |
| publishDate | 2023-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Engineering |
| spelling | doaj.art-ac2c791530f143a4b6a911e2acc533de2023-01-05T04:32:37ZengElsevierResults in Engineering2590-12302023-03-0117100860Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & densityAns Al Rashid0Muammer Koç1Division of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha, Qatar; Corresponding author.Division of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha, Qatar; Faculty of Engineering, University of Karabük, Karabük 78050, TurkeyThe optimum selection of process parameters, materials, and product design is essential to achieve the desired response of 3D-printed structures, especially in functional components. The current practices of the experimental optimization process require significant resources, which can be limited through numerical modeling and simulation techniques. In this study, a thermomechanical numerical model is used to predict the performance of the additive manufacturing (AM) process, i.e., fused filament fabrication (FFF). 3D printing (3DP) process simulations were performed for tensile testing coupons using carbon fiber-reinforced polyamide-6 (PA6-CF) material. The numerical model predicted the effect of infill patterns and densities on the deflections and distortions during the FFF process. The numerical model predictions were validated via experiments performed under similar conditions. The results conclude that the numerical model can adequately predict the process-induced deflections and distortions during the FFF process. Generally, higher dimensional control was observed for rectangular infill patterns and increased infill density. However, the numerical model overestimates the shrinkage as the stress-relaxation effect is not considered in the numerical model and underestimates the warpages as perfect build plate adhesion is assumed.http://www.sciencedirect.com/science/article/pii/S2590123022005308Fused filament fabricationProcess simulationDimensional analysisPolymer compositesWarpage |
| spellingShingle | Ans Al Rashid Muammer Koç Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density Results in Engineering Fused filament fabrication Process simulation Dimensional analysis Polymer composites Warpage |
| title | Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density |
| title_full | Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density |
| title_fullStr | Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density |
| title_full_unstemmed | Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density |
| title_short | Experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process: Effect of infill design & density |
| title_sort | experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process effect of infill design amp density |
| topic | Fused filament fabrication Process simulation Dimensional analysis Polymer composites Warpage |
| url | http://www.sciencedirect.com/science/article/pii/S2590123022005308 |
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