Methodological recommendations are proposed for the development of the process of topological optimization of load carrying structures adapted for the use of additive technologies. The stage of postprocessing of the polygonal geometry of the part generated as a result of optimization is considered in detail. The validation stage is included in the process of topological optimization by comparing the calculated and experimental data to assess the operability (strength) of the optimized structure. For the option of manufacturing load carrying structures by 3D printing, it is planned to conduct studies of the mechanical properties of the material obtained on a 3D printer, taking into account the printing settings and the orientation of the material layers relative to the applied load during testing. An example of approbation of the proposed methodological recommendations is given on the example of a load carrying hook included in the design of a wheeled transport anti-ram device. The optimization was performed in the SolidThinking Inspire software environment (Altair Engineering, USA). The results of the calculated and experimental determination of the destructive load are presented for the initial and optimized hook design. For the experiment, the hooks were made of ABS plastic using FDM technology. Finite element models of hooks were developed in the ANSYS Workbench software package (ANSYS, USA). Assignment of material properties, boundary conditions and applied load is performed in the LS-PrePost application, calculation in the LS-DYNA solver (ANSYS, USA). The calculated and experimental efficiency estimates were 44.4 and 57.8 %, i.e. their difference is within 13.4 %. The zones and the nature of the destruction identified by calculation and experimentally completely coincide. The results obtained confirm the correctness of the proposed methodological recommendations, the selected modeling approaches and the determination of the properties of the material of the structure manufactured by 3D printing.
The paper introduces the results of an experimental study of the mechanical characteristics of 3D printed ABS plastic ABSplus-P430 samples under tension. These 3D printed samples differ in the orientation of the material layers, formed by the position of the samples when printed, and the print raster pattern. During the tests, the material showed isotropic properties in terms of Young’s modulus and anisotropic properties for elongation at break, yield strength, and ultimate strength. We revealed that the print orientation relative to the direction of the applied load significantly affects the strength of the tested samples. Using the obtained test results, the specified parameters of the bilinear model of the material were identified by performing a series of computational studies using computer finite element models of material samples. The found parameters of the bilinear model of the material can be used to carry out computational estimation of the strength and bearing capacity of ABS plastic products manufactured by 3D printing. The results obtained also make it possible to develop recommendations for the orientation of products in the printing area according to the criterion of ensuring the greatest strength, taking into account the loading mode of the product.
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