Modeling time-dependent anisotropy in MEX component-scale process simulation

Modeling time-dependent anisotropy in MEX component-scale process simulation

DI NARDO Mario Emanuele, FRÖLICH Felix, KÄRGER Luise, CARLONE Pierpaolo

Abstract. In this paper, a numerical method is proposed to consider the transient anisotropic orientation state of a material extruded (MEX) part during a macroscale process simulation. To enhance computational efficiency, multiple filament strands are considered within single finite elements. The model is constructed around the utilization of 4th order orientation tensors, obtained by combining the information of the nozzle toolpath and the mesh elements in accordance with the process time. This provides a dynamic mapping of the anisotropic material orientation state within each element, in real-time to the process trajectory. Through the integration of time-dependent orientation tensors, this research provides deeper insights into filaments alignment evolution during the MEX process. This advancement not only enhances predictive capabilities in process simulation but also streamlines computational demands.

Keywords
Additive Manufacturing, FFF, Process Simulation, FEM, Filament Orientation, Material Anisotropy, Homogenization

Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: DI NARDO Mario Emanuele, FRÖLICH Felix, KÄRGER Luise, CARLONE Pierpaolo, Modeling time-dependent anisotropy in MEX component-scale process simulation, Materials Research Proceedings, Vol. 41, pp 603-612, 2024

DOI: https://doi.org/10.21741/9781644903131-67

The article was published as article 67 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] Gibson, I., Rosen, D. W., Stucker, B., Khorasani, M., Rosen, D., Stucker, B., & Khorasani, M. (2021). Additive manufacturing technologies (Vol. 17, pp. 160-186). Cham, Switzerland: Springer. https://doi.org/10.1007/978-3-030-56127-7
[2] Kaur, G., Singari, R. M., & Kumar, H. (2022). A review of fused filament fabrication (FFF): Process parameters and their impact on the tribological behavior of polymers (ABS). Materials Today: Proceedings, 51, 854-860. https://doi.org/10.1016/j.matpr.2021.06.274
[3] Li, J., Yang, S., Li, D., & Chalivendra, V. (2018). Numerical and experimental studies of additively manufactured polymers for enhanced fracture properties. Engineering Fracture Mechanics, 204, 557-569. https://doi.org/10.1016/j.engfracmech.2018.11.001
[4] Rashid, A. A., & Koç, M. (2021). Fused filament fabrication process: a review of numerical simulation techniques. Polymers, 13(20), 3534. https://doi.org/10.3390/polym13203534
[5] Jin, Y. A., He, Y., Fu, J. Z., Gan, W. F., & Lin, Z. W. (2014). Optimization of tool-path generation for material extrusion-based additive manufacturing technology. Additive manufacturing, 1, 32-47. https://doi.org/10.1016/j.addma.2014.08.004
[6] Ahn, S. H., Montero, M., Odell, D., Roundy, S., & Wright, P. K. (2002). Anisotropic material properties of fused deposition modeling ABS. Rapid prototyping journal, 8(4), 248-257. https://doi.org/10.1108/13552540210441166
[7] Cattenone, A., Morganti, S., Alaimo, G., & Auricchio, F. (2019). Finite element analysis of additive manufacturing based on fused deposition modeling: Distortions prediction and comparison with experimental data. Journal of Manufacturing Science and Engineering, 141(1), 011010. https://doi.org/10.1115/1.4041626
[8] Brenken, B., Favaloro, A., Barocio, E., DeNardo, N. M., & Pipes, R. B. (2016, May). Development of a model to predict temperature history and crystallization behavior of 3D printed parts made from fiber-reinforced thermoplastic polymers. In Int. SAMPE Tech. Conf (Vol. 12, p. 704).
[9] Zhou, Y., Lu, H., Wang, G., Wang, J., & Li, W. (2020). Voxelization modelling based finite element simulation and process parameter optimization for Fused Filament Fabrication. Materials & Design, 187, 108409. https://doi.org/10.1016/j.matdes.2019.108409
[10] Ahn, S. H., Baek, C., Lee, S., & Ahn, I. S. (2003). Anisotropic tensile failure model of rapid prototyping parts-fused deposition modeling (FDM). International Journal of Modern Physics B, 17(08n09), 1510-1516. https://doi.org/10.1142/S0217979203019241
[11] Domingo-Espin, M., Puigoriol-Forcada, J. M., Garcia-Granada, A. A., Llumà, J., Borros, S., & Reyes, G. (2015). Mechanical property characterization and simulation of fused deposition modeling Polycarbonate parts. Materials & Design, 83, 670-677. https://doi.org/10.1016/j.matdes.2015.06.074
[12] Biswas, P., Guessasma, S., & Li, J. (2020). Numerical prediction of orthotropic elastic properties of 3D-printed materials using micro-CT and representative volume element. Acta Mechanica, 231(2), 503-516. https://doi.org/10.1007/s00707-019-02544-2
[13] Zhao, Y., Chen, Y., & Zhou, Y. (2019). Novel mechanical models of tensile strength and elastic property of FDM AM PLA materials: Experimental and theoretical analyses. Materials & Design, 181, 108089. https://doi.org/10.1016/j.matdes.2019.108089
[14] Kanatani, K. (1984). Distribution of directional data and fabric tensors. International journal of engineering science, 22(2), 149-164. https://doi.org/10.1016/0020-7225(84)90090-9
[15] Advani, S. G., & Tucker III, C. L. (1987). The use of tensors to describe and predict fiber orientation in short fiber composites. Journal of rheology, 31(8), 751-784. https://doi.org/10.1122/1.549945
[16] Lebedev, L. P., Cloud, M. J., & Eremeyev, V. A. (2010). Tensor analysis with applications in mechanics. World Scientific. https://doi.org/10.1142/7826
[17] Heller, B. P., Smith, D. E., & Jack, D. A. (2017). Simulation of planar deposition polymer melt flow and fiber orientation in fused filament fabrication. In 2017 International Solid Freeform Fabrication Symposium. University of Texas at Austin.
[18] Lupone, F., Padovano, E., Venezia, C., & Badini, C. (2022). Experimental Characterization and Modeling of 3D Printed Continuous Carbon Fibers Composites with Different Fiber Orientation Produced by FFF Process. Polymers, 14(3), 426. https://doi.org/10.3390/polym14030426
[19] Python Documentation, Meshio Package, Available on 08/12/2023, Information on: https://pypi.org/project/meshio/
[20] Abaqus 6.14 documentation, User Subroutines Reference Guide, Available on 08/12/20023, Information on: https://130.149.89.49:2080/v6.14/