Experimental and numerical investigation on 3D printed PLA sacrificial honeycomb cladding

Rebelo, Hugo Bento; Lecompte, David; Cismasiu, Corneliu; Jonet, Arnaud; Belkassem, Bachir; Maazoun, Azer

doi:10.1016/j.ijimpeng.2019.05.013

Cited by 60 publications

(26 citation statements)

References 34 publications

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“…It showed a promising beginning in biomedical applications including tissue engineering, scaffolds, drug delivery and implantable devices [9]. In addition, its light weight and relatively higher stiffness are suitable for light weight designs in numerous emerging applications including cellular parts, sacrificial cladding [10,11]. However, the high brittle and low toughness properties have limited its applications.…”

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confidence: 99%

The influence of stiffener geometry on flexural properties of 3D printed polylactic acid (PLA) beams

et al. 2020

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We used finite element analyses (FEA) on Abaqus to study flexural properties of additive manufactured beams using polylactic acid (PLA) polymer. Experimental stress–strain data from flexural testing are used to define elastic–plastic properties of the material in the computation software. The flexural experiments are used to validate the FEA approach suggested. The method provides good results of deflection and stress with errors well below 10% in most of the cases. Therefore, by using the proposed approach, costs related to repeated experimental works can be avoided. In addition, the flexural rigidities of the additive manufactured beams are studied. Five different beam stiffener designs (diamond, honeycomb, square, triangular and wiggle) are studied based on beam bending theory. The force–deflection data from the flexural tests are used to determine the area moments of inertia of the beams. The honeycomb stiffener showed the highest force–deflection behaviour that led to the highest calculated area moment of inertia. However, with the lowest force–deflection behaviour, the square stiffener had the lowest calculated area moment of inertia.

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confidence: 99%

The influence of stiffener geometry on flexural properties of 3D printed polylactic acid (PLA) beams

et al. 2020

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“…The observation was local buckling of the 3D printed cells' walls that have been reported as the primary failure mode. [31][32][33] The effect of the infill pattern type used in the 3D printing process, as well as the number of the layers that are covering the 3D printed object, whether from the top and bottom surfaces or the sides walls, has a significant impact in the final stiffness and strength of the produced object.…”

Section: Literature Reviewmentioning

confidence: 99%

“…32 It is also reported that honeycomb structures have a shape recovery effect which has been studied by cyclic compression tests; with circle honeycomb structure having the highest strength compared to the typical hexagonal honeycomb structure when number of sides of the polygon increases from a three-sided triangle to a six-sided hexagon and until the polygon finally develops into a circle, 25 and compared to other traditionally used materials, the honeycomb structure represents sacrificial cladding that yields exceptional values of energy dissipation. 31 Not only does the re-entrant honeycomb core stabilize the structure and increase impact energy, but also leads to consistent performance under multi-cyclic impacts. 37 The capability of energy absorption is one of the key characteristics to study for sandwich structures.…”

Section: Literature Reviewmentioning

confidence: 99%

“…41,45 Moreover, incorporating numeral techniques can be used as an essential tool to develop further in the field of the nonlinear response of sandwich composites which is vital for predicting hyperelasticity and large strain values accurately as well as thermomechanical response data. 22,31,45,46 Therefore, with several advantages such as low density and high mechanical performance, sandwich structures can be classified as a significant innovation in the field of multifunctional composite structural materials with promising developments alongside employing 3D printing techniques.…”

Section: Literature Reviewmentioning

confidence: 99%

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Mechanical performance of three-dimensional printed sandwich composite with a high-flexible core

Ahmed

Alnajjar

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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This paper aims to investigate experimentally and using finite element analysis the performance of using three-dimensional printing technology to produce a composite sandwich panel that is made of the high-flexible core as well as with high stiffness upper and lower surfaces made of a glass fiber reinforced composite filament. There are many advantages of using sandwich structures in many applications, especially the aerospace field, where the high stiffness to strength and the lightweight is the most preferred in such applications. The conventional manufacturing methods that are used to produce sandwich panels are limited to particular core geometry, whereas manufacturing a composite core is not possible by these traditional production methods. So by using additive manufacturing technology, it becomes more applicable to design a combination of different geometries and materials to achieve properties that have never been made before, especially combining flexibility and high energy absorption keeping high strength to failure. A central deflection to a length of 0.26 is observed within the elastic zone, a remarkable ratio in beams that reflects the three-dimensional printed sandwich beams’ capability with a highly flexible core to absorb energy that would open doors for many industrial applications that is attributed to the lowest flexural rigidity (167E-3Pa · m4) of the sandwich by using the TriHex infill pattern. In contrast, the Gyroid infill structure could afford the highest central load (0.264 kN). At the peak load applied on the sandwich beam, a maximum error of 5.4% is estimated by finite element analysis lower than the experimental values.

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“…All compression simulations were run for a 90.0 s duration with the minimum mesh size and time steps set at 0.24 mm and 100 ns, respectively. Cells were considered to fail when the strain rate of the material exceed 10% since 5% to 10% criteria are typically adopted in PLA compression tests [22].…”

Section: In-plane Honeycomb Compression Testmentioning

confidence: 99%

A Study on Shock Absorption Characteristics of Honeycomb-Inserted Bollards

et al. 2020

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Lack of shock absorption capability of conventional steel bollards causes significant vehicle damage and, consequently, high repair costs. This research studies a solution to reduce vehicle damage by inserting polylactic acid (PLA) honeycomb structures. A honeycomb-inserted bollard was designed based on numerical simulations using LS-DYNA, which yielded the bollard designed for actual vehicle-bollard collision experiments. Simulation efforts were focused on calculating the acceleration characteristics when a vehicle collides with steel and honeycomb-inserted bollards. Compared to the simulated steel bollards, 20 MPa yield-strength honeycomb-inserted bollard showed 0.017 s delay in the maximum acceleration occurrence time, reduction of the maximum acceleration of 37.4% of that of steel bollards, and a 13.1% reduction in the B-pillar maximum acceleration. Actual vehicle-bollard collision experiments, with a gyro-sensor installed at the test vehicle front bumper frame, also proved improved shock absorption characteristics of the honeycomb-inserted bollards. An experiment with honeycomb-inserted bollard showed a 0.783 s delay in the maximum acceleration occurrence time, a significant delay when compared to steel bollards. The maximum acceleration measured by the gyro-sensor was 0.35 × 103 m/s2 when the simulation predicted it to be 0.388 × 103 m/s2, proving the similarity in the simulations and experiments. Thus, this study of shock absorption characteristics promised reduced damage to vehicles and lower repair cost.

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Experimental and numerical investigation on 3D printed PLA sacrificial honeycomb cladding

Cited by 60 publications

References 34 publications

The influence of stiffener geometry on flexural properties of 3D printed polylactic acid (PLA) beams

The influence of stiffener geometry on flexural properties of 3D printed polylactic acid (PLA) beams

Mechanical performance of three-dimensional printed sandwich composite with a high-flexible core

A Study on Shock Absorption Characteristics of Honeycomb-Inserted Bollards

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