Effective Design of the Graded Strut of BCC Lattice Structure for Improving Mechanical Properties

In order improve the poor mechanical properties of the body-centred cubic (BCC) lattice structure, which suffers from the stress concentration effects at the nodes of the BCC unit cell, a graded-strut design method is proposed to increase the radii corner of the BCC nodes, which can obtain a new graded-strut body-centred cubic (GBCC) unit cell. After the relative density equation and the force model of the structure are obtained, the quasi-static uniaxial compression experiments and finite element analysis (FEA) of GBCC samples and BCC samples are performed. The experimental results show that for the fabricated samples with the same relative density, the GBCC can increase the initial stiffness by at least 38.20%, increase the plastic failure strength by at least 34.12%, compared with the BCC. Coupled experimental and numerical results not only suggest that the GBCC has better mechanical and impact resistance properties than the BCC, but also indicate that as the radii corner increases, the stress concentration effect at the node and the mechanical properties will be improved, which validates the proposed design method for graded-strut unit cells and can provide guidance for the design and future research on ultra-light lattice structures in related fields.