Comparison of FEA simulations and experimental results for as-built additively manufactured dogbone specimens

Baikerikar, Prathamesh; Turner, Cameron J.

doi:10.1007/s00170-021-07307-9

Cited by 4 publications

(2 citation statements)

References 22 publications

(19 reference statements)

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“…We have postulated three key reasons for this discrepancy: the material model definition, surface roughness and geometrical deviation, and the possible internal defects. The considered material model, indeed, neglects the anisotropy caused by the manufacturing process that can lead to anisotropic material response in the specimen [44].…”

Section: Comparison Between Experimental and Numerical Resultsmentioning

confidence: 99%

Design and Analysis of Energy Absorbent Bioinspired Lattice Structures

Greco

Buccino

et al. 2023

J Bionic Eng

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The increasing demand for energy absorbent structures, paired with the need for more efficient use of materials in a wide range of engineering fields, has led to an extensive range of designs in the porous forms of sandwiches, honeycomb, and foams. To achieve an even better performance, an ingenious solution is to learn how biological structures adjust their configurations to absorb energy without catastrophic failure. In this study, we have attempted to blend the shape freedom, offered by additive manufacturing techniques, with the biomimetic approach, to propose new lattice structures for energy absorbent applications. To this aim we have combined multiple bio-inspirational sources for the design of optimized configurations under compressive loads. Periodic lattice structures are fabricated based on the designed unit cell geometries and studied using experimental and computational strategies. The individual effect of each bio-inspired feature has been evaluated on the energy absorbance performance of the designed structure. Based on the design parameters of the lattices, a tuning between the strength and energy absorption could be obtained, paving the way for transition within a wide range of real-life applicative scenarios.

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Section: Comparison Between Experimental and Numerical Resultsmentioning

confidence: 99%

Design and Analysis of Energy Absorbent Bioinspired Lattice Structures

Greco

Buccino

et al. 2023

J Bionic Eng

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“…More precisely, the contact force is affected by the vertical extrusion velocity, horizontal moving speed, the diameter of the nozzle, the melting temperature, the distance between the material surface and the extruder (Comminal et al , 2018; Xia et al , 2018). Conventionally, finite element analysis is used to predict the 3D printed part’s deformation and residual stress under such a complex physical environment (Baikerikar and Turner, 2021; Brenken et al , 2019; Samy et al , 2021). Software such as Abaqus TM , Ansys TM and COMSOL TM can be used to simulate the FDM processes of very simple geometries (thin walls and squares) when using powerful parallel computing resources.…”

Section: Problem Formulationmentioning

confidence: 99%

Lightweight design of two-level supports for extrusion-based additive manufacturing based on metaheuristic algorithms

Feng

Jiang²,

Thakur³

et al. 2022

RPJ

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Purpose Two-level support with Level 1 consisting of a set of beams and Level 2 consisting of a tree-like structure is an efficient support structure for extrusion-based additive manufacturing (EBAM). However, the literature for finding a slim two-level support is rare. The purpose of this paper is to design a lightweight two-level support structure for EBAM. Design/methodology/approach To efficiently solve the problem, the lightweight design problem is split into two subproblems: finding a slim Level 1 support and a slim Level 2 support. To solve these two subproblems, this paper develops three efficient metaheuristic algorithms, i.e. genetic algorithm (GA), genetic programming (GP) and particle swarm optimization (PSO). They are problem-independent and are powerful in global search. For the first subproblem, considering the path direction is a critical factor influencing the layout of Level 1 support, this paper solves it by splitting the overhang region into a set of subregions, and determining the path direction (vertical or horizontal) in each subregion using GA. For the second subproblem, a hybrid of two metaheuristic algorithms is proposed: the GP manipulates the topologies of the tree support, while the PSO optimizes the position of nodes and the diameter of tree branches. In particular, each chromosome is encoded as a single virtual tree for GP to make it easy to manipulate Crossover and Mutation. Furthermore, a local strategy of geometric search is designed to help the hybrid algorithm reach a better result. Findings Simulation results show that the proposed method is preferred over the existing method: it saves the materials of the two-level support up to 26.34%, the materials of the Level 1 support up to 6.62% and the materials of the Level 2 support up to 37.93%. The proposed local strategy of geometric search can further improve the hybrid algorithm, saving up to 17.88% of Level 2 support materials. Research limitations/implications The proposed approach for sliming Level 1 support requires the overhanging region to be a rectilinear polygon and the path direction in a subregion to be vertical or horizontal. This limitation limits the further material savings of the Level 1 support. In future research, the proposed approach can be extended to handle an arbitrary overhang region, each with several choices of path directions. Practical implications The details of how to integrate the proposed algorithm into the open-source program CuraEngine 4.13.0 is presented. This is helpful for the designers and manufacturers to practice on their own 3D printers. Originality/value The path planning of the overhang is a critical factor influencing the distribution of supporting points and will thus influence the shape of the support structure. Different from existing approaches that use single path directions, the proposed method optimizes the volume of the support structure by planning hybrid paths of the overhangs.

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Exploring Flexural Performances of Fused Filament Fabrication 3D-Printed ABS and ABS-Composites through Innovative Bio-Inspired Processing Parameter Optimization

Wang,

Zhou,

2024

Appl Compos Mater

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Comparison of FEA simulations and experimental results for as-built additively manufactured dogbone specimens

Cited by 4 publications

References 22 publications

Design and Analysis of Energy Absorbent Bioinspired Lattice Structures

Design and Analysis of Energy Absorbent Bioinspired Lattice Structures

Lightweight design of two-level supports for extrusion-based additive manufacturing based on metaheuristic algorithms

Exploring Flexural Performances of Fused Filament Fabrication 3D-Printed ABS and ABS-Composites through Innovative Bio-Inspired Processing Parameter Optimization

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