Micromechanical analysis of honeycomb parts built by the FDM process

• Grant number: 16/17835-6
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: January 01, 2017
• End date: September 01, 2019
• Field of knowledge: Engineering - Mechanical Engineering - Mechanics of Solids
• Principal Investigator: Rafael Thiago Luiz Ferreira
• Grantee: Rafael Quelho de Macedo
• Host Institution: Divisão de Engenharia Mecânica (IEM). Instituto Tecnológico de Aeronáutica (ITA). Ministério da Defesa (Brasil). São José dos Campos , SP, Brazil
• Associated scholarship(s): 17/22123-8 - Mechanical properties optimization of parts built by FDM through micromechanical modelling, BE.EP.DR

Abstract

The objective of this work is to develop a micromechanical model to analyse printed parts fabricated by Fused Deposition Modelling (FDM) filled with honeycomb pattern. The micromechanical analysis is based on defining a representative volume element, where appropriate structural analysis by finite elements is carried out to obtain the effective elastic properties and also microstructural stresses due to external loads, in order to build failure envelopes of the printed part. It is been reported in the literature that printing parameters, such as layers thickness, raster angle, air gap and others influence the printed material characteristics. In addition, the heat transfer phenomenon during the printing process originates thermal residual stresses that affect the final geometry and mechanical properties of the printed part. This study aims to insert such effects in the microstructural analysis, to evaluate how they influence the mechanical properties and failure characteristics of the printed part. With this model in hand, the printing parameters can be varied in the micromechanical model in order to achieve desired mechanical properties. The numerical analyses will be validated by experiments. Moreover, functional parts can be built with the FDM process using new materials. Examples are polymers with embedded chopped and continuous carbon fibers. These materials require proper failure criteria and an appropriate micromechanical model, like the one being searched, can provide that.

Scientific publications

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

DE MACEDO, RAFAEL QUELHO; LUIZ FERREIRA, RAFAEL THIAGO; GLEADALL, ANDREW; ASHCROFT, IAN. VOLCO-X: Numerical simulation of material distribution and voids in extrusion additive manufacturing. ADDITIVE MANUFACTURING, v. 40, APR 2021. (17/09419-5, 17/22123-8, 16/17835-6)