Failure analysis of 3D printed woven composite plates with holes under tensile and shear loading

Abstract

This paper presents the modelling and failure analysis of 3D printed woven composite plates with a hole under tensile and shear loading. In the finite element (FE) software, woven cells are built using stacking sequences, which are then linked together to form the FE model of the woven laminate. According to the 3D printing experiments, tailored fibre placement is achieved in the simulation by altering the fibre orientation around a region to leave a hole. In order to compare this placement technique with that of a control group, 'drilled' samples with the notch removed via mechanical machining was proposed. Three cases, open-hole laminates under tensile loading and double-shear and single-shear loading, are studied to advance the understanding of the failure mechanisms. Good agreement between numerical and experimental results has been obtained, which exhibits a similar trend of strength improvement using new placement technique. The distribution of principal strain and displacement in the modelling are consistent with the results obtained from Digital Image Correlation (DIC) and Micro X-ray Computed Tomography (Micro-CT). It suggests that the avoidance of fibre breakage and the overlap of printed materials around the hole can dramatically increase

Fibre bridging and nozzle clogging in 3D printing of discontinuous carbon fibre-reinforced polymer composites: coupled CFD-DEM modelling

“…Apart from the traditional manufacturing methods, the recently emerged additive manufacturing techniques (AM, also known as 3D printing) have shown the potential to enable low-cost and mould-free manufacturing of threedimensional objects with complex geometries [3]. Among them, the extrusion-based fused filament fabrication (FFF) printing is the most popular process (by number of machines), which fabricates a part by melting and depositing the composite material layer by layer [4]. Due to the favourable melt processability, a wide variety of thermoplastic can be used as the matrix materials in the FFF 3D printing of composites, such as acrylonitrile butadiene styrene plastic (ABS), polylactic acid (PLA) and nylon.…”

Permanent Deformation and Stiffness Degradation of Open Hole Glass/PA6 UD Thermoplastic Composite in Tension and Compression

“…With this, the fibers are not cut and run continuously through the material. This usually results in an increased notched and bearing strength, as shown in [ 7 , 8 ] for carbon/PA6.…”

Pin-bearing mechanical behaviour of continuous reinforced Kevlar fibre composite fabricated via fused filament fabrication

“…Ascione et al proposed a bearing strength prediction model for glass fibre reinforced composite [23]. Comparing bearing resistance of CRFC produced with additive manufacturing respect to conventional technique it was found that best results are achieved with AM if the hole is produced subsequently by drilling process [24,25]. The reason can be ascribed to the technological limitations of the AM process: to create a hole by an additive approach the so-called wall layers circumscribing the hole itself are mandatory.…”