Numerical Modeling Based on Finite Element Analysis of 3D-Printed Wood-Polylactic Acid Composites: A Comparison with Experimental Data (original) (raw)
Related papers
Defects and residual stresses finite element prediction of FDM 3D printed wood/PLA biocomposite
The International Journal of Advanced Manufacturing Technology
The exploited enthusiasm within the research community for harnessing PLA-based biocomposites in fused deposition modeling (FDM) is spurred by the surging demand for environmentally sustainable and economically viable materials across diverse applications. While substantial strides have been taken in unravelling the intricacies of the process-structure–property relationship, the intricate interdependencies within this context remain only partially elucidated. This current gap in knowledge presents formidable obstacles to achieving the pinnacle of quality and dimensional precision in FDM-fabricated specimens crafted from biocomposites. Despite the existence of numerous numerical models for simulating the FDM process, an unmistakable need exists for models that are custom-tailored to accommodate the distinct characteristics inherent to biocomposites. As a reaction to those pressing needs, this study presents a 3D coupled thermomechanical numerical model designed to predict dimensions...
IOP Conference Series: Materials Science and Engineering, 2019
Mechanical properties of parts from fused filament fabrication has been made known to be directionally dependent or in other word anisotropy. Several common process parameters were varied to study their impact on the mechanical properties, in particular compression and bending strength of the end product in the material of wood PLA. The Taguchi method was used to design and simplify the experiment without compromising the experiment’s efficiency. S/N ratio from Taguchi analysis was interpreted for determining the optimum combination of process parameter for the highest compressive and bending strength. The build orientation angle is the major factor contributing to higher compression and bending strength recorded followed by infill density and lastly layer thickness. The maximum value for compressive stress is 98.9 MPa with 0° built orientation, 0.15mm layer thickness and 60% infill, while for bending stress it is 73.6 MPa with 0° built orientation, 0.20mm layer thickness and 100% i...
International Journal of Automotive and Mechanical Engineering
Additive manufacturing is gaining popularity nowadays due to its applications in the automotive, medical, aerospace industries, and sports to manufacture complex parts. Fused deposition modelling is an additive manufacturing process utilised widely due to its lower cost, fast prototyping and faster production time. The present study focuses on applying FDM to the composite material filament and the impact of parameters of FDM on the part quality. A composite filament material was prepared to combine PLA (Poly-lactic Acid) and banana fibre. Specimens were prepared using this composite filament by varying various parameters such as layer thickness, infiltration and build orientation. Flexural and tensile tests were performed as per standards. It was found that the material properties considered are significantly affected by percentage infill and build orientation. The ‘on edge’ build orientation provides better material properties as compared to the other two orientations. The tensile...
A case study of wood thermoplastic composite filament for 3D printing
BioResources, 2021
The 3D printing technology is a method of converting proposed complex geometric shapes into solid models. One of these methods is the FDM (fused deposition modeling) printing technology as a considerably affordable and the most commonly used method in the world. The purpose of this study is to obtain FDM 3D printer filaments that are as natural as possible, resembling wood and evoking the sensation of wood upon touching through deployment of bio-based plastics and additives. Polylactic acid (PLA) and bio thermoplastic polyurethane (TPU) were used as matrices, and lignin and Arboform, a lignin-based biomaterial, were used as additives. The characteristics of composites achieved through addition of 10% lignin and Arboform to matrices were identified by differential scanning calorimetry (DSC) thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and the tensile test. The effects of some printing parameters on the mechanical characteristics were also determined. Lignin i...
Effect of wood content in FDM filament on properties of 3D printed parts
Materials Today Communications, 2018
The effect of wood content in 3D printing materials on the properties of 3D printed parts was investigated. Six filaments using polylactic acid (PLA) with varying loading levels of wood particles from 0 % to 50 % by weight were produced and used for 3D printing. The density of the filaments and 3D printed parts used in this study slightly decreased with increasing wood content. The tensile strength of the filaments increased from 55 MPa to 57 MPa with an addition of 10 % wood, but decreased with higher levels of wood content to 30 MPa for filaments with 50 % wood content. The surface of the parts printed from the filament without the addition of wood was smoother and the printed part had no voids within the structure. With increasing wood content the surface becomes rougher, more voids were present, and had visible clusters of wood particles (due to wood particle clustering and clogging in the printer nozzle). Higher wood content in 3D printed parts decreased the storage modulus. 2 measured with torsional loading on a rheometer, but did not change the glass transition temperature.
Polymers, 2022
Fused Deposition Modelling (FDM) is an actively growing additive manufacturing (AM) technology due to its ability to produce complex shapes in a short time. AM, also known as 3-dimensional printing (3DP), creates the desired shape by adding material, preferably by layering contoured layers on top of each other. The need for low cost, design flexibility and automated manufacturing processes in industry has triggered the development of FDM. However, the mechanical properties of FDM printed parts are still weaker compared to conventionally manufactured products. Numerous studies and research have already been carried out to improve the mechanical properties of FDM printed parts. Reinforce polymer matrix with fiber is one of the possible solutions. Furthermore, reinforcement can enhance the thermal and electrical properties of FDM printed parts. Various types of fibers and manufacturing methods can be adopted to reinforce the polymer matrix for different desired outcomes. This review emphasizes the fiber types and fiber insertion techniques of FDM 3D printed fiber reinforcement polymer composites. A brief overview of fused deposition modelling, polymer sintering and voids formation during FDM printing is provided, followed by the basis of fiber reinforced polymer composites, type of fibers (synthetic fibers vs. natural fibers, continuous vs. discontinuous fiber) and the composites’ performance. In addition, three different manufacturing methods of fiber reinforced thermoplastics based on the timing and location of embedding the fibers, namely ‘embedding before the printing process (M1)’, ‘embedding in the nozzle (M2)’, and ‘embedding on the component (M3)’, are also briefly reviewed. The performance of the composites produced by three different methods were then discussed.
Development and Application of Wood Flour-Filled Polylactic Acid Composite Filament for 3D Printing
Materials (Basel, Switzerland), 2017
This paper presents the development of wood flour (WF)-filled polylactic acid (PLA) composite filaments for a fused deposition modeling (FDM) process with the aim of application to 3D printing. The composite filament consists of wood flour (5 wt %) in a PLA matrix. The detailed formulation and characterization of the composite filament were investigated experimentally, including tensile properties, microstructure, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and X-ray diffraction (XRD). The feedstock filaments of this composite were produced and used successfully in an assembled FDM 3D printer. The research concludes that compared with pure PLA filament, adding WF changed the microstructure of material fracture surface, the initial deformation resistance of the composite was enhanced, the starting thermal degradation temperature of the composite decreased slightly, and there were no effects on the melting temperature. The WF/PLA composite filament is sui...
3D printed composite materials mechanical property , 2021
Additive Manufacturing (AM) is the process of manufacturing parts by joining materials ‘layer by layer’ from Computer-Aided Design (CAD) model data. AM processes support faster product realization and modeling for a wide variety of products in many industries. The Fused Deposition Modeling (FDM) process is an AM process that builds a product from thin layers of extruded filaments from semi-melted materials such as a thermoplastic. The advantages related to additive manufacturing (AM)/3D printing are the reduction of raw material being utilized, reduced energy consumption, less time-related process planning and set up, as well as the ability to fabricate complex and novel geometries, and internal structures, that would be difficult or impossible to manufacture using conventional manufacturing. Regardless of the advantages the presence of voids, poor interfacial bonding between adjacent layers, and higher dependency of process parameters are the disadvantages of AM which affect the mechanical properties of the final product. As an important upstream, the focus of this study is mainly on fused deposition molding (FDM) techniques of AM to investigate the effects of process parameters (layer height, raster width, printing speed, and air-gap), and voids on the mechanical behaviors of a composite material of pure PA (polyamide), fiber-reinforced composites of PA-CF (Carbon Fiber- Polyamide) and PA-GF (glass fiber- Polyamide). The thesis also investigates the evolution of voids through the tensile test. ASTM D638-14 Type IV tensile specimens were studied with both experimentally and Abaqus CAE simulation. The experiment designed by using Taguchi orthogonal array and the results from the experiment were analyzed by ANOVA analysis, and SEM microstructures analysis through ImageJ and volume fraction of voids as per ASTM: D2734-09 standard to specify the percentage of voids for each specimen. The experimental analysis of volume fraction of voids and tensile test have shown the layer height and printing speed have a significant effect on the creation of voids for all the studied materials (PA, PA-CF, and PA-GF). Findings of this work show that 11% and 9% of volume fraction of void increment were observed when the layer height goes from 0.2 to 0.48 for PA-CF and PA-GF, respectively, as well as the voids in the mechanical properties, have decreased with the increasing of layer height and printing speed. Furthermore, the raster width and air-gap have less effect as compared with the two major parameters. Some smaller voids are eliminated and relatively larger voids are enlarged during the evolution of voids. Within this process, the geometry of voids is changed, and the volume of voids was decreasing because of the elongation of nominal length smaller voids and air inclusions were dissolved through the length of a specimen. The results of the experimental investigation were used with the commercial software ABAQUS/CAE to develop a tensile model of the above three materials. The tensile specimen part was developed using ABAQUS/CAE composite, and compared with an experimental result. In the deformed part obtained, a good agreement between the results of simulation and experimental results was obtained, which suggested that the Abaqus/CAE model can predict the properties of composite structures, and its results are closer to the real forming situation. Keywords:-3D printing; mechanical properties; Voids; composite materials; composite material modeling and simulation
Fused Deposition Modelling of Natural Fibre/Polylactic Acid Composites
Journal of Composites Science, 2017
Fused deposition modelling is a simple additive manufacturing technology utilising fine filament extrusion of predominantly thermoplastic materials to build 3D objects layer by layer. This research explores the feasibility and the factors involved in using fused deposition modelling to produce natural fibre reinforced composite components. Uniform 3-mm filaments of both hemp and harakeke (Phormium tenax) in varying weight percentages within polylactic acid (PLA) polymer were successfully produced and used to print tensile test samples. Tensile test results supported harakeke to be a useful fibre in terms of mechanical properties achieved which surpassed the Young’s modulus and tensile strength of plain PLA samples by 42.3% and 5.4%, respectively.