Process-Structure Coupled Simulation of Additive Manufactured Components.

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Fused Filament Fabrication (FFF) is a widely used 3D printing method.
• Understanding the mechanical properties of FFF parts is crucial for their application.
• Component geometry and printing parameters significantly influence material behavior.

Purpose of the Study:

• To investigate the influence of extrusion infill angles on the mechanical properties of 3D printed polylactide (PLA) specimens.
• To analyze the directional dependence and elastoplastic behavior considering the real component geometry.
• To validate Finite Element Method (FEM) simulations for predicting the mechanical performance of FFF parts.

Main Methods:

• Manufacturing of PLA specimens with varying infill angles using FFF.
• Computed Tomography (CT) scanning to capture the real component geometry.
• Mechanical testing with an optical measuring system and FEM simulations of scanned components.

Main Results:

• Significant differences observed between the real geometry behavior and the initial design model.
• Geometric deviations lead to increased stiffness, ultimate tensile strength, and strain at failure.
• The criterion of maximum principal strain proved suitable for evaluating component strength.

Conclusions:

• Real geometry significantly affects the mechanical properties of FFF parts, deviating from idealized models.
• FEM simulations incorporating actual geometry can accurately predict mechanical performance.
• The maximum principal strain criterion is effective for strength assessment in FFF components.