In this study, a continuous glass fiber-reinforced composite is manufactured using the vacuum assisted resin transfer molding (VARTM) process. The composite is manufactured from an S-glass fiber acting as reinforcement and an epoxy resin as matrix. Unlike a traditional E-glass fiber reinforcement, S-glass fibers give higher stiffness and provide easier manufacturability due to the value of the refractive index of S-glass lying within the range of refractive indices of the epoxy resin. The epoxy resin is synthesized Epon 826, Epalloy 5200, and hexahydropthalic anhydride and tailored to match refractive indices of the S-glass fibers. After synthesis of the resin, composite panels are manufactured from the synthesized epoxy resin and S-glass fibers with a bi-directional [0°/90°] 8-harness satin weave. VARTM process was utilized to manufacture the composite panels. Composite panels are visually inspected for transparency, and tensile, flexural, and impact testing is performed. Mechanical tests showed consistent results for tensile modulus, tensile strength, flexural modulus, flexural strength, and impact damage resistance.
Purpose
The purpose of this paper is to study the flexural behavior of additively manufacture Ultem 1010 parts. Fused deposition modeling (FDM) process has become one of most widely used additive manufacturing methods. The process provides the capability of fabricating complicated shapes through the extrusion of plastics onto a print surface in a layer-by-layer structure to build three-dimensional parts. The flexural behavior of FDM parts are critical for the evaluation and optimization of both material and process.
Design/methodology/approach
This study focuses on the performance of FDM solid and sparse-build Ultem 1010 specimens. Flexure tests (three-point bend) are performed on solid-build coupons with varying build orientation and raster angle. These parameters are investigated through a full-factorial design of experiments (DOE) to determine optimal build parameters. Air gap, raster width and contour width are held constant. A three-dimensional nonlinear finite element model is built to simulate the flexural behavior of the FDM parts.
Findings
Experimental results include flexure properties such as yield strength and modulus, as well as analysis of the effect of change in build parameters on material properties. The sparse-build FDM parts chosen from the experimental tests are simulated based on this developed model. Thermo-mechanical simulation results show that the finite element simulation and experimental tests are in good agreement. The simulation can be further extended to other complicated FDM parts.
Originality/value
From the DOE study, sparse-build coupons with specific build parameters are fabricated and tested for the validation of a finite element simulation.
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