An elastic‐inelastic model and embedded bounce‐back control for layered printing with cementitious materials

Abstract

This paper presents a finite‐deformation model for extrusion‐based layered printing with cementitious materials. The evolution of mechanical properties as the printed material cures and stiffens results in nonphysical reduction in the magnitude of elastic strains when standard constitutive models are employed. This elastic recovery of the printing induced deformation contradicts the experimentally observed behavior of the printed cementitious materials that harden at a nearly‐frozen deformed state. A thermodynamically motivated constraint on the evolution of elastic strains is imposed on the constitutive model to remedy the nonphysical bounce‐back effect. An algorithm that is based on a strain‐projection technique for the elastic part of deformation is developed that complements the inelastic response given by the Drucker–Prager model. It is then embedded in a finite strain finite element framework for the modeling and simulation of cure hardening and inelastic response of the early age cementitious materials. A ghost mesh method is proposed for continuous layer‐wise printing of the material without the need for intermittent mesh generation technique or adaptive remeshing methods. The model is validated via comparison with experimental data and representative test cases are presented that investigate the mathematical and computational attributes of the proposed model.