Experimental characterization and finite element simulation of FDM 3D printed polymer composite tooling for sheet metal stamping

Athale, Madhura; Park, Taejoon; Hahnlen, Ryan; Pourboghrat, Farhang

doi:10.1007/s00170-022-09801-0

Cited by 7 publications

(12 citation statements)

References 38 publications

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“…Many previous works on FDM-printed materials highlighted that the material generally exhibits an orthotropic plastic behavior besides its elastic orthotropic one [ 8 , 10 , 19 , 25 ]. By dealing with metallic materials, the orthotropic yield condition could be described with Hill’s criterion.…”

Section: Modeling Methodologymentioning

confidence: 99%

“…Many research studies have focused on the characterization of the mechanical properties of FDM parts using tensile tests [ 6 , 7 , 8 , 9 ]. The raster angle of the specimens was varied to investigate the dependence from the direction tested of elastic moduli [ 10 , 11 , 12 , 13 ], tensile elastic limits [ 7 , 10 , 14 ], and tensile ultimate strengths [ 7 ]. The results show a great difference between the mechanical properties in various directions, displaying the strong anisotropy that characterizes FDM-printed parts.…”

Section: Introductionmentioning

confidence: 99%

“…Many research works have attempted to model the behavior of FDM parts, mainly focusing on elastic properties [ 11 , 15 ] and ultimate tensile strength [ 16 , 17 , 18 ], achieving interesting results. The plastic behavior of FDM materials has also been investigated and some works proposed strategies to describe it [ 10 , 19 ]; however, this aspect is particularly difficult to model due to the lack of understanding of this phenomenon. Hill formalized a yield criterion for anisotropic materials, taking metal rolled sheets as a reference [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

“…Hill formalized a yield criterion for anisotropic materials, taking metal rolled sheets as a reference [ 20 ]. Some authors proposed using Hill’s anisotropic yield criterion to model the transition from elastic fields to plastic fields and the successive plastic deformation through an isotropic hardening rule [ 10 , 19 ]. The results showed that numerical predictions can be quite accurate and can satisfactorily represent the material behavior.…”

Section: Introductionmentioning

confidence: 99%

“…The results showed that numerical predictions can be quite accurate and can satisfactorily represent the material behavior. However, only a few attempts were made to use finite element analysis as a design or verification tool [ 10 ], highlighting the need to improve the understanding of material models that are capable of representing FDM parts, especially in terms of their plastic and failure behavior.…”

Section: Introductionmentioning

confidence: 99%

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Elasto-Plastic Mechanical Modeling of Fused Deposition 3D Printing Materials

2023

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Fused deposition modeling (FDM) is one of the most common 3D printing technologies and is becoming a well-established production method. Short fiber-reinforced polymers represent a new class of printing materials that enhance the mechanical properties of final components, thus informing an interesting subject of analysis for this study. FDM-printed parts are characterized by a strong anisotropy, so their behavior should be analyzed accordingly. The authors proposed a modeling strategy based on a transversely isotropic behavior hypothesis, representing material behaviors associated with an elasticity matrix in relation to the elastic field and a combination of Hill’s yield criterion and Voce’s isotropic hardening law for the plastic field. Material properties of materials were experimentally identified through tensile tests on dog bone specimens printed with different orientations in space. The numerical model was then calibrated using the finite element software LS-DYNA and the optimization software LS-OPT. An agreement between numerical and experimental results showed the robustness of the modeling strategy proposed to describe the stress behaviors of printed materials until a maximum load is reached, while strain behaviors have yet to be correctly defined due to the difficulties associated with evaluating an equivalent deformation.

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