Integrated design and additive manufacturing of lattice-filled multi-cell tubes

Liu, Yisen; Tan, Qianbing; Lin, Hao; Wang, Jin; Wang, Kui; Peng, Yong; Yao, Song

doi:10.1016/j.compscitech.2023.110252

Cited by 25 publications

(4 citation statements)

References 70 publications

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“…Lightweight materials such as honeycomb sandwich, aluminum foam and lattice structures have been used to fill thin-walled structures to improve energy absorption [10,11]. However, the effectiveness of mixing tube travelling and energy absorption of the structure are limited due to issues with traditional fillers such as honeycomb and metal foam materials, which suffer from poor design ability and high randomness in preparation.…”

Section: Introductionmentioning

confidence: 99%

Crashworthiness Study of Functional Gradient Lattice-Reinforced Thin-Walled Tubes under Impact Loading

Liu,

Wang,

Liang

et al. 2024

Materials

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Creating lightweight and impact-resistant box structures has been an enduring pursuit among researchers. A new energy-absorbing structure consisting of a bionic gradient lattice-enhanced thin-walled tube is presented in this article. The gradient lattice and thin-walled tube were prepared using selective laser melting (SLM) and wire-cutting techniques, respectively. To analyze the effects of gradient pattern, mass ratio, diameter range and impact speed on structural crashworthiness, low-speed impact at 4 m/s and finite element simulation experiments were conducted. The study demonstrates that the design of inward radial gradient lattice-reinforced thin-walled tubes can effectively enhance structure’s energy-absorption efficiency and provide a more stable mode of deformation. It also shows a 17.44% specific energy-absorption advantage over the uniformly lattice-reinforced thin-walled tubes, with no significant overall gain in peak crushing force. A complex scale evaluation method was used to determine the optimum structure and the structure type with the best crashworthiness was found to be a gradient lattice-filled tube with a thickness of 0.9 mm and a slope index of 10. The gradient lattice-reinforced thin-walled tube suggested in this investigation offers guidance for designing a more efficient thin-walled energy-absorption structure.

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Section: Introductionmentioning

confidence: 99%

Crashworthiness Study of Functional Gradient Lattice-Reinforced Thin-Walled Tubes under Impact Loading

Liu,

Wang,

Liang

et al. 2024

Materials

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“…AM is employed to create prototypes or final parts with either simple or complex geometries. This manufacturing process entails depositing layers of material and constructing solid parts with precise geometric shapes 4,5 . The process begins with a computer‐aided design model, which is then sliced into layers of equal thickness to ensure high quality and resolution 6 …”

Section: Introductionmentioning

confidence: 99%

Effects of TPU on the mechanical properties, fracture toughness, morphology, and thermal analysis of 3D‐printed ABS‐TPU blends by FDM

Soltanmohammadi,

Rahmatabadi,

Aberoumand

et al. 2024

Vinyl Additive Technology

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In this paper, blends of ABS‐TPU with two different weight percentages of TPU were prepared using fused deposition modeling technology. The effect of adding TPU on the fracture toughness of ABS and mechanical properties was comprehensively studied. Tensile, compression, fracture toughness, and shear tests were conducted on the 3D‐printed samples. Thermal and microstructural analyses were performed using dynamic mechanical thermal analysis (DMTA), and scanning electron microscope (SEM). The DMTA results showed that adding TPU decreased the storage modulus and the glass transition temperature of ABS, as well as its peak intensity. The mechanical test results showed that adding TPU decreased the strength but increased the formability and elongation of the samples. Fracture tests showed that the addition of TPU decreased the maximum force needed for a crack to initiate. The force required for crack initiation decreased from 568.4 N for neat ABS to 335.3 N for ABS80 and 123.2 N for ABS60. The ABS60 blend exhibited the highest strength against crack growth, indicating that TPU can change the behavior of ABS from brittle to ductile. Shear test results and SEM images also showed good adhesion strength between the printed samples for all three specimens, indicating their good printability. Adding TPU resulted in a reduction in the size and number of voids and holes between the printed layers.Highlights Melt mixing, filament preparation, and 3D printing of ABS‐TPU blends. Investigation of mechanical properties, microstructure, and fracture toughness. Improved resistance to crack growth and elongation by adding TPU to ABS. Improving printability and reducing microholes in blends compared with ABS. Achieving a wide range of mechanical properties for various applications.

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“…These factors became obstacles to the development of continuous fiber reinforced polymer honeycomb structures (CFRPHSs). However, 3D printing techniques with high design freedoms and multi-scale molding capabilities allow a non-mold-based approach to manufacturing structures with customized materials and complex geometric shapes, providing the possibility for the integrated manufacturing of CFRPHSs [24][25][26]. According to the ISO/ASTM 52900 standard, 3D printing technologies are divided into seven types, among which material extrusion (MEX) technology is very suitable for 3D printing of polymers [27,28].…”

Section: Introductionmentioning

confidence: 99%

Path Planning and Bending Behaviors of 3D Printed Continuous Carbon Fiber Reinforced Polymer Honeycomb Structures

Wang,

Liu

et al. 2023

Polymers

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Continuous fiber reinforced polymer composites are widely used in load-bearing components and energy absorbers owing to their high specific strength and high specific modulus. The path planning of continuous fiber is closely related to its structural defects and mechanical properties. In this work, continuous fiber reinforced polymer honeycomb structures (CFRPHSs) with different printing paths were designed and fabricated via the fused deposition modeling (FDM) technique. The investigation of fiber dislocation at path corners was utilized to analyze the structural defects of nodes caused by printing paths. The lower stiffness nodes filled with pure polymer due to fiber dislocation result in uneven stiffness distribution. The bending performance and deformation modes of CFRPHSs with different printing paths and corresponding pure polymer honeycomb structures were investigated by three-point bending tests. The results showed that the enhancement effect of continuous fibers on the bending performance of honeycomb structures was significantly affected by the printing paths. The CFRPHSs with a staggered trapezoidal path exhibited the highest specific load capacity (68.33 ± 2.25 N/g) and flexural stiffness (627.70 ± 38.78 N/mm). In addition, the fiber distributions and structural defects caused by the printing paths determine the stiffness distribution of the loading region, thereby affecting the stress distribution and failure modes of CFRPHSs.

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Integrated design and additive manufacturing of lattice-filled multi-cell tubes

Cited by 25 publications

References 70 publications

Crashworthiness Study of Functional Gradient Lattice-Reinforced Thin-Walled Tubes under Impact Loading

Crashworthiness Study of Functional Gradient Lattice-Reinforced Thin-Walled Tubes under Impact Loading

Effects of TPU on the mechanical properties, fracture toughness, morphology, and thermal analysis of 3D‐printed ABS‐TPU blends by FDM

Path Planning and Bending Behaviors of 3D Printed Continuous Carbon Fiber Reinforced Polymer Honeycomb Structures

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