Development of functional gradient multi-material composites using Poly Lactic Acid and walnut shell reinforced Poly Lactic Acid filaments by fused filament fabrication technology

Palaniyappan, Sabarinathan; Gnanavelbabu, A.; Sivakumar, Narain Kumar; Prahadeeswaran, M

doi:10.1016/j.jobe.2022.105746

Cited by 15 publications

(10 citation statements)

References 36 publications

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“…20 There are similar types of wood fillers reinforced polymer composites industrialized by various investigators. 21,22 It is fact, that the AM components are better than the injection-molded products in terms of mechanical and physical properties. 23 The main purpose of AM is to reduce the amount of material usage and processing time.…”

Section: Introductionmentioning

confidence: 99%

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Influence of printing-based factors on the mechanical properties of hexagonal lattice-structured 3D printed novel walnut shell/polylactic acid composite

Mathiazhagan¹,

Sivakumar²,

Palaniyappan

et al. 2023

Journal of Thermoplastic Composite Materials

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The incorporation of bio-based natural fillers and lattice structures in thermoplastic polymer has superior advantages such as a reduction in the usage of conventional polymers with improved damping and mechanical properties. The present work focuses on the development of Walnut Shell/PLA (WSP) lattice-structured composite by the Fused Filament Fabrication technique. The flexural strength, compression strength, and thickness error properties of the hexagon lattice-structured WSP composites are optimized by varying Printing-Based Factors (PBFs) which include infill density (60%, 80%, and 100%), nozzle temperature (190°C, 210°C, and 230°C), printing speed (10 mm/sec, 20 mm/sec, and 30 mm/sec), and layer height (0.1 mm, .2 mm, and .3 mm). The flexural and compression test experiments were conducted as per the ASTM D790 and ASTM D695 standards. The process optimization of the measured responses is made by using Taguchi grey relational grade optimization technique. The experimental outcomes such as compressive and flexural strength and minimal dimensional error are converted into the Grey Relational Grade (GRG) for the optimization process. The results show that the Signal-to-Noise ratio (S/N) from the measured GRG clearly shows that, the lower layer height of 0.1 mm, higher nozzle temperature of 230°C, higher infill density of 100%, and average printing speed of 20 mm/sec is an optimal experimental condition for attaining higher strengths and lower errors. From the Analysis of Variance (ANOVA) analysis, the printing temperature, and layer height are the most persuasive PBFs for the mechanical and physical characteristics with respect to the incorporated lattice structure. The optimized experimental conditions develop maximum flexural and compressive strengths of 4.98 MPa and 28.19 MPa, in addition to a lower thickness error of .186 mm obtained for hexagon lattice-structured WSP biopolymeric composites.

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Section: Introductionmentioning

confidence: 99%

“…20 There are similar types of wood fillers reinforced polymer composites industrialized by various investigators. 21,22…”

Section: Introductionmentioning

confidence: 99%

Influence of printing-based factors on the mechanical properties of hexagonal lattice-structured 3D printed novel walnut shell/polylactic acid composite

Mathiazhagan¹,

Sivakumar²,

Palaniyappan

et al. 2023

Journal of Thermoplastic Composite Materials

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“…6 The AM practice is widely classified into various classes with reference to the ASTM F2792 standards. 7 Among the numerous additive manufacturing methodologies, the fused filament fabrication (FFF) methodology is preferred to create polymeric lattice structures with enhanced strength-to-weight ratio. 8 The FFF technique emphases on creating the polymeric components by layering material in a step-by-step manner with the 3D model's topology.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, there are some evidences stating that, the AM polymeric components are superior to the conventional polymeric components in term of mechanical strength 6 . The AM practice is widely classified into various classes with reference to the ASTM F2792 standards 7 . Among the numerous additive manufacturing methodologies, the fused filament fabrication (FFF) methodology is preferred to create polymeric lattice structures with enhanced strength‐to‐weight ratio 8 .…”

Section: Introductionmentioning

confidence: 99%

Topological design factor optimization in the development of periodic‐type honeycomb lattice structure on the carbon fiber reinforced polyethylene terephthalate glycol composite

Palaniyappan,

Sivakumar,

Sikder

et al. 2023

Polymer Composites

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In most of the automobile and aerospace materials, cellular structures are extensively used due to their lightweight and high energy absorption capabilities. Naturally available animal bones and plant stems are light in weight due to their natural cellular structures. This may inspire various researchers for integrating the various lattice structures such as beam, planar, triply periodic minimal surfaces, and voronoi structures on the various structural materials. The development of lattice structures using 3D printing technology has opened up major attention towards fabricating lightweight components without any complications. In this study, the detailed crashworthiness responses such as compressive strength was optimized in terms of varying the topology‐related factors on the carbon fiber reinforced polyethylene terephthalate glycol (CF/PETG) composite. The experimentation was conducted concerning variable topology factors such as shell thickness, unit cell type, wall thickness (WT), unit cell orientation (UCO), skewing angle, and unit cell size. The model was examined and optimized by means of the Taguchi optimization technique. The crashworthiness response was analyzed using the compression test and moreover, this experimental response is used for the optimization processes. From the observation, the topology factors which contributed more for the higher compressive strength will be UCO of 65.47% and WT of 15.20%. Results of the regression study show that the R square value with concern to the compressive strength will be 92.74%. The optimized design parametric condition for CF/PETG composite established a higher compressive strength of 41.179 MPa, From the overall results, it is clear that the variation in the topology factors has developed a huge and favorable impact on the mechanical characteristics of the lattice‐structured CF/PETG polymer composite.Highlights Hexagonal Lattice structure incorporation on the carbon fiber reinforced PETG composite. Design optimization on the compressive properties. Taguchi optimization is performed on design‐based lattice structures. Unit cell orientation has higher percentage contribution on compressive strength.

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“…12 FFF involves layerby-layer deposition of material to create components and has been widely used in industries such as aerospace, biomedical, automobile, and construction. 13,14 The research towards the development of tubes by FFF technique is less concentrated and a few of them are listed. Tabacu et al developed a circular thin-walled structure filled with rectangular cellular structures.…”

Section: Introductionmentioning

confidence: 99%

Crushing behavior optimization of octagonal lattice‐structured thin‐walled 3D printed carbon fiber reinforced PETG (CF/PETG) composite tubes under axial loading

Sivakumar,

Palaniyappan,

Vishal

et al. 2023

Polymer Composites

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Thin‐walled structures with good energy absorption capability can significantly use as energy absorbers in passive vehicle safety systems. The present study deals with designing and developing thin‐walled carbon fiber (CF) reinforced PETG (polyethylene terephthalate glycol) composite tubes with octagonal corrugated lattice structures on the lateral surfaces. The FFF (fused filament fabrication) factors such as layer height, nozzle temperature, printing speed, line width, and infill density were optimized. The experiment outcomes such as compressive strength and dimensional length error, are measured for the respective octagonal corrugated lattice structure incorporated in 3D printed CF/PETG composite tubes. The results proclaimed that, the optimum factors for improved compressive strength in the octagonal corrugated lattice‐structured CF/PETG composite will be 0.1 mm layer height, 220°C nozzle temperature, 20 mm/sec printing speed, 0.1 mm line width and 100% infill density. Furthermore, the R‐square value for the compressive strength and dimensional length error is within an acceptable limit of 91.25% and 93.31%. So, the developed mathematical models are in good form for practical acceptance. The optimized condition3D printed samples exhibit better compressive strength and lower dimensional length deviation, which is essential for considering it in the safety protection application in automotive components.Highlights• 3D printed octagonal shaped lattice structured PETG/CF composite tube.• Process parameters were optimized in terms of compressive strength.• Layer height has contributed a major impact on the compressive strength response.

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Development of functional gradient multi-material composites using Poly Lactic Acid and walnut shell reinforced Poly Lactic Acid filaments by fused filament fabrication technology

Cited by 15 publications

References 36 publications

Influence of printing-based factors on the mechanical properties of hexagonal lattice-structured 3D printed novel walnut shell/polylactic acid composite

Influence of printing-based factors on the mechanical properties of hexagonal lattice-structured 3D printed novel walnut shell/polylactic acid composite

Topological design factor optimization in the development of periodic‐type honeycomb lattice structure on the carbon fiber reinforced polyethylene terephthalate glycol composite

Crushing behavior optimization of octagonal lattice‐structured thin‐walled 3D printed carbon fiber reinforced PETG (CF/PETG) composite tubes under axial loading

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