Process-Structure Coupled Simulation of Additive Manufactured Components

In this work, the influence of extrusion infill angles on the mechanical properties of 3D printed (Fused Filament Fabrication, FFF) test specimens are investigated, considering the real geometry of the components. Therefore, various polylactide (PLA) specimens with different infill angles are manufactured, scanned by Computed Tomography (CT) and further investigated by mechanical testing using an optical measuring system. This allows the directional dependence and the elastoplastic behavior of the material to be demonstrated. It was found that the real geometry behavior differs significantly from the model. In addition to the tests Finite Element Method (FEM) simulations of the scanned components are carried out in order to provide a prediction of the mechanical properties of FFF-printed parts for component manufacturers. The conducted simulations have shown that the geometric deviation leads to an increase in stiffness, a higher ultimate tensile strength and strain at failure. The main objective of this work is to evaluate the stiffness and strength of FFF-printed components using FEM with an economically justifiable testing effort. This includes not only the evaluation of the directional dependence, considering the real geometry of the components, but also the evaluation of a suitable strength criterion. The criterion of maximum principal strain has proved to be suitable.