Layer Time Optimization in Large Scale Additive Manufacturing Via a Reduced Physics-Based Model

Liu, Lu; Jo, Eonyeon; Hoskins, Dylan; Vaidya, Uday; Ozcan, Soydan; Feng, Jianhua; Kim, Seokpum

doi:10.2139/ssrn.4286822

Cited by 2 publications

(2 citation statements)

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“…The FEs are activated gradually as the amount of filament is deposited. 35,36 Also, thermal boundary conditions are applied to compute the temperature evolution. The minimum voxel size must be equal to the layer thickness.…”

Section: Methodsmentioning

confidence: 99%

Integrated computational modeling of large format additive manufacturing: Developing a digital twin for material extrusion with carbon fiber-reinforced acrylonitrile butadiene styrene

Castelló-Pedrero,

García-Gascón,

Bas-Bolufer

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part L:

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Material extrusion (MEX) continues to be a pivotal additive manufacturing (AM) process, involving the selective heating and layer-by-layer deposition of material. However, conventional finite-element models (finite-element analysis) face limitations in accurately simulating the MEX process, highlighting the need for experimental validation. This paper highlights an advanced material modeling technology that streamlines the development of composite parts using large format AM (LFAM). It specifically focuses on a thermoplastic acrylonitrile butadiene styrene (ABS) matrix composite material enriched with 20% short carbon fibers. The study employs integrated computational materials engineering, integrating (i) the manufacturing process, (ii) the material’s microstructure, (iii) homogenization techniques, and (iv) the performance of the final part. The development of a digital twin for pellet extrusion is proposed, emphasizing the importance of micro-structure characterization to account for warpage and residual stresses that lead to part distortion. The demonstrator manufactured for this study is a wind turbine mold of a blade section. Experimental tests revealed an elastic modulus of 5.5 GPa and a hardening modulus of 2.4 GPa for the composite. The numerical microscopic model showed a 16% error in the elastic modulus compared to experimental results. The study concludes that the homogenization techniques are effective in predicting the elastic properties but lack accuracy in the plastic region. The application of the model to the LFAM process of pellet extrusion is demonstrated, with simulation results showing a maximum deformation close to the center of the wind turbine blade mold.

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Section: Methodsmentioning

confidence: 99%

Integrated computational modeling of large format additive manufacturing: Developing a digital twin for material extrusion with carbon fiber-reinforced acrylonitrile butadiene styrene

Castelló-Pedrero,

García-Gascón,

Bas-Bolufer

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…The G-code used to 3D print each lattice is taken from slicer and converted into deposition path coordinate data. 47 The fiber orientation directions were then assigned to each FE based on these deposition paths as shown in Figure 4A. The material properties were calibrated using previous experimental results [48][49][50] and summarized in Table 1.…”

Section: Finite Element Analysismentioning

confidence: 99%

Compression and energy absorption characteristics of short fiber‐reinforced 2D composite lattices made by material extrusion

Kim

Насиров

Pokkalla

et al. 2023

Engineering Reports

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With the advent of additive manufacturing, lattice structures have been of increasing interest for engineering applications involving light‐weighting and energy absorption. Several studies have investigated mechanical properties of various lattices made up of mostly unreinforced polymers and lack numerical analysis for reinforced lattice structures. In this paper, mechanical response of short fiber reinforced lattice structures under compression is investigated through experiments and numerical simulations. Three different 2D lattices namely, square grid, honeycomb, and isogrid along with their rotated counterparts were fabricated using 15% wt carbon fiber‐acrylonitrile butadiene styrene and experimentally evaluated through uniaxial compression testing up to 30% strain. As simulations on fiber‐reinforced lattices under large compressive strains are rarely performed and published, finite element models accounting for fiber orientation induced anisotropic mechanical properties and geometrical imperfections were developed to predict the stress–strain characteristics up to 30% compressive strains. The stress–strain curves predicted from the numerical simulations matches well with the experimental responses for various lattice geometries. Various failure mechanisms such as thin strut buckling, contact within the lattice, and fracture of struts under large deformation were investigated. Analyzing energy absorption characteristics of these lattices revealed that the honeycomb structures in horizontal configuration exhibits superior energy absorption capability.

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Layer Time Optimization in Large Scale Additive Manufacturing Via a Reduced Physics-Based Model

Cited by 2 publications

References 0 publications

Integrated computational modeling of large format additive manufacturing: Developing a digital twin for material extrusion with carbon fiber-reinforced acrylonitrile butadiene styrene

Integrated computational modeling of large format additive manufacturing: Developing a digital twin for material extrusion with carbon fiber-reinforced acrylonitrile butadiene styrene

Compression and energy absorption characteristics of short fiber‐reinforced 2D composite lattices made by material extrusion

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