Evolution and new horizons in modeling crack mechanics of 3D printing polymeric structures

He, Feiyang; Thakur, Vijay Kumar; Khan, Muhammad Atif

doi:10.1016/j.mtchem.2020.100393

Cited by 19 publications

(15 citation statements)

References 134 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Due to its safe, fast, and effective operation, freedom of customisation, and cost-effectiveness, FDM has become the most widely used AM process in customised and low-volume production industries [ 3 ]. Apart from functional prototyping, FDM is also used in aerospace, automotive, medical and biomechanical sectors [ 4 , 5 , 6 , 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, it is significant to evaluate the fatigue performance of the material. Safai et al Shanmugam et al and He et al reviewed the fatigue behaviour of FDM polymeric materials [ 8 , 32 , 33 ]. The results of their overview show that determining the best printing parameter combinations for fatigue strength is a challenge because of the synergism between variables and 3D printed material properties.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Effects of Printing Parameters on the Fatigue Behaviour of 3D-Printed ABS under Dynamic Thermo-Mechanical Loads

Khan

2021

Polymers

Self Cite

View full text Add to dashboard Cite

Fused deposition modelling (FDM) is the most widely used additive manufacturing process in customised and low-volume production industries due to its safe, fast, effective operation, freedom of customisation, and cost-effectiveness. Many different thermoplastic polymer materials are used in FDM. Acrylonitrile butadiene styrene (ABS) is one of the most commonly used plastics owing to its low cost, high strength and temperature resistance. The fabricated FDM ABS parts commonly work under thermo-mechanical loads in actual practice. For producing FDM ABS components that show high fatigue performance, the 3D printing parameters must be effectively optimized. Hence, this study evaluated the bending fatigue performance for FDM ABS beams under different thermo-mechanical loading conditions with varying printing parameters, including building orientations, nozzle size, and layer thickness. The combination of three building orientations (0°, ±45°, and 90°), three nozzle sizes (0.4, 0.6, and 0.8 mm) and three-layer thicknesses (0.05, 0.1, and 0.15 mm) were tested at different environmental temperatures ranging from 50 to 70 °C. The study attempted to find the optimal combination of the printing parameters to achieve the best fatigue behaviour of the FDM ABS specimen. The experiential results showed that the specimen with 0° building orientation, 0.8 mm filament width, and 0.15 mm layer thickness vibrated for the longest time before the fracture at each temperature. Both a larger nozzle size and thicker layer height can increase the fatigue life. It was concluded that printing defects significantly decreased the fatigue life of the 3D-printed ABS beam.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effects of Printing Parameters on the Fatigue Behaviour of 3D-Printed ABS under Dynamic Thermo-Mechanical Loads

Khan

2021

Polymers

Self Cite

View full text Add to dashboard Cite

show abstract

“…In addition, the X building orientation, higher layer thicknesses, and larger nozzle size values provide the lowest C and m values because C and m values are directly related to FCG rate. These results are realistic due to the material type and environmental temperature influence on crack growth [9]. However, the overall trend in C and m values was higher than in previous research [28,29].…”

Section: Discussionmentioning

confidence: 39%

“…It is layer-by-layer printing, based on computer-aided design (CAD) and computer-aided manufacturing (CAM) [8]. Moreover, the most common materials used in this method are polymers because of their distinguished properties with low cost and light weight, making them suitable for essential applications, such as aircraft wings and wind blades [9].…”

Section: Introductionmentioning

confidence: 99%

Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Alshammari

Khan

2021

Polymers

Self Cite

View full text Add to dashboard Cite

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

show abstract

“…In most cases, the periodic lattice structures contain periodically repeating unit cells with mechanical properties that can be easily customized. Random stochastic foams, the first generation of manmade porous-isotropic materials, have been widely used in impact energy absorption applications and elastic cushioning applications [1,20,21]. Comparing the two cellular structures shows that the mechanical properties of periodic lattice structures are superior to their stochastic counterparts.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties and Energy Absorption Characteristics of Additively Manufactured Lightweight Novel Re-Entrant Plate-Based Lattice Structures

et al. 2021

Self Cite

View full text Add to dashboard Cite

In this work, three novel re-entrant plate lattice structures (LSs) have been designed by transforming conventional truss-based lattices into hybrid-plate based lattices, namely, flat-plate modified auxetic (FPMA), vintile (FPV), and tesseract (FPT). Additive manufacturing based on stereolithography (SLA) technology was utilized to fabricate the tensile, compressive, and LS specimens with different relative densities (ρ). The base material’s mechanical properties obtained through mechanical testing were used in a finite element-based numerical homogenization analysis to study the elastic anisotropy of the LSs. Both the FPV and FPMA showed anisotropic behavior; however, the FPT showed cubic symmetry. The universal anisotropic index was found highest for FPV and lowest for FPMA, and it followed the power-law dependence of ρ. The quasi-static compressive response of the LSs was investigated. The Gibson–Ashby power law (≈ρn) analysis revealed that the FPMA’s Young’s modulus was the highest with a mixed bending–stretching behavior (≈ρ1.30), the FPV showed a bending-dominated behavior (≈ρ3.59), and the FPT showed a stretching-dominated behavior (≈ρ1.15). Excellent mechanical properties along with superior energy absorption capabilities were observed, with the FPT showing a specific energy absorption of 4.5 J/g, surpassing most reported lattices while having a far lower density.

show abstract

Evolution and new horizons in modeling crack mechanics of 3D printing polymeric structures

Cited by 19 publications

References 134 publications

Effects of Printing Parameters on the Fatigue Behaviour of 3D-Printed ABS under Dynamic Thermo-Mechanical Loads

Effects of Printing Parameters on the Fatigue Behaviour of 3D-Printed ABS under Dynamic Thermo-Mechanical Loads

Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Mechanical Properties and Energy Absorption Characteristics of Additively Manufactured Lightweight Novel Re-Entrant Plate-Based Lattice Structures

Contact Info

Product

Resources

About