Finite element modelling of 3D printed continuous carbon fiber composites: Embedded elements technique and experimental validation

Avanzini, Andrea; Battini, Davide; Giorleo, Luca

doi:10.1016/j.compstruct.2022.115631

Cited by 23 publications

(16 citation statements)

References 33 publications

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“…The 2D Shell simulation and embedded elements displayed prediction errors of 7.69% and 4.72%, respectively, compared to the tensile test. These errors are consistent with those observed by Avanzini et al, 32 who found errors ranging from 2.2%–3.5% and 0.9%–3.6% for the 2D shell simulation and embedded elements, respectively. When the experimental specimen reaches its failure load, the simulation shows maximum stresses of 81 MPa and 3350 MPa for the matrix (Onyx) and fibers, respectively (Figures 17(a) and (b)).…”

Section: Resultsmentioning

confidence: 97%

Study of 3D-printed onyx parts reinforced with continuous glass fibers: Focus on mechanical characterization, analytical prediction and numerical simulation

Nikiema,

Balland,

Sergent

2024

Journal of Composite Materials

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The 3D printing of continuous-fiber composites is currently relevant to engineers and researchers. This study aims to characterize and predict the mechanical properties of Onyx/glass fiber specimens printed using 3D printing. The work assesses the impact of glass fiber printing parameters on the mechanical behavior of printed parts and proposes analytical and numerical methods to predict mechanical properties. A physicochemical analysis was conducted on 3D printed continuous glass fibers. The study also investigated the impact of fiber printing parameters on composite parts. The results indicate that the 3D-printed glass fibers consist of nylon, continuous glass fibers, and voids (porosity), which range from 58% to 63%, 31% to 38%, and 5% to 8%, respectively. Mechanical characterizations indicate that printing fiber layers in blocks results in superior mechanical properties compared to printing alternating layers of glass fibers and Onyx. Additionally, the concentric mode of fiber printing can be challenging if the ‘start rotation’ parameter is not adjusted correctly. Premature specimen breakage occurred when fiber printing began within their useful length, resulting in a deformation at break that was approximately 34% less, depending on the starting position. The proposed analytical and numerical prediction methods had prediction errors of approximately 7% to 12% and 5% to 7%, respectively. Engineers can use these prediction approaches during the dimensioning phase of 3D printed composite parts.

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Section: Resultsmentioning

confidence: 97%

Study of 3D-printed onyx parts reinforced with continuous glass fibers: Focus on mechanical characterization, analytical prediction and numerical simulation

Nikiema,

Balland,

Sergent

2024

Journal of Composite Materials

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“…79,87 The finite element prediction method (FEM) should be developed to analyze 3D printed CNFRCs, which could better represent the damage evolution process of the composites. 88,89 Furthermore, it was paramount to underscore the necessity of incorporating theoretical computational models that aptly account for the distinctive attributes characteristic of 3D printed CNFRCs. These models were indispensable tools for the in-depth exploration of the mechanical properties underpinning this specialized class of composite materials.…”

Section: Limitation and Future Outlookmentioning

confidence: 99%

“…However, it was imperative to recognize that while the ML paradigm furnished ultimate predictive outcomes, it inherently lacked the capacity to elucidate the analytical trajectory or the evolution process of damage within the fabricated composites 79,87 . The finite element prediction method (FEM) should be developed to analyze 3D printed CNFRCs, which could better represent the damage evolution process of the composites 88,89 . Furthermore, it was paramount to underscore the necessity of incorporating theoretical computational models that aptly account for the distinctive attributes characteristic of 3D printed CNFRCs.…”

Section: Limitation and Future Outlookmentioning

confidence: 99%

3D printing continuous natural fiber reinforced polymer composites: A review

Cheng,

Peng,

Wang

et al. 2023

Polymers for Advanced Techs

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With the growing prominence of environmental conservation awareness, there has been a notable surge in the exploration of renewable materials, particularly in the realm of natural fiber reinforced polymer composites. This heightened focus is underscored by the recent advancements in additive manufacturing techniques dedicated to continuous natural fiber reinforced composites (CNFRCs), which have inherently opened unprecedented avenues for the holistic customization of CNFRCs with meticulously tailored properties. This work reviewed the advanced techniques for 3D printing CNFRCs and addressed their challenges and perspectives in the future. First, the 3D printing processes of CNFRCs were reviewed, and the use of reinforcement and matrix phases was classified in detail. Then, CNFRCs were discussed in terms of their mechanical performances and novel function of shape‐changing. Further, performance optimization and prediction methods of 3D printed CNFRCs were discussed. In conclusion, a perspective on future study opportunities of 3D printed CNFRCs was provided from design, manufacturing, prediction to application.

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“…Following [ 19 ], this can be disregarded in most cases when shear weak materials are used. An alternative to the approach of using principal directions is presented by Avanzini et al [ 20 ]. They applied the embedded elements method, the effectiveness of which could not be sufficiently verified.…”

Section: Introductionmentioning

confidence: 99%

Load-Oriented Nonplanar Additive Manufacturing Method for Optimized Continuous Carbon Fiber Parts

Kipping

Schüppstuhl

2023

Materials

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The process of the additive manufacturing (AM) of carbon-fiber-reinforced polymer (CFRP) parts based on the process of fused deposition modeling (FDM) has seen considerable research in recent years, which amplifies the importance of adapted slicing and pathplanning methods. In particular, load-oriented techniques are of high interest when employing carbon fiber materials, as classical methods, such as tape-laying and laminating, struggle with highly curved and complex geometries and require the costly production of molds. While there have been some promising propositions in this field, most have restricted themselves to a planar slicing approach, which severely limits the ability to place the fibers along stress paths. In this paper, a nonplanar slicing approach is presented that utilizes principal stress directions to construct optimized nonplanar constituting layers on which pathplanning can be carried out. These layers are oriented such that the effect of the weak interlayer adhesion is minimized. Support material is adaptively generated to enable the use of arbitrary part geometry. Furthermore, a continuous pathplanning method and post-processor are applied to yield manufacturing instructions. The approach is verified for its viability of application through experimental investigation on a multi-axis robotic 3D printer. This constitutes an important step in allowing the fabrication of CFRP parts to further utilize the possibilities of additive manufacturing.

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Finite element modelling of 3D printed continuous carbon fiber composites: Embedded elements technique and experimental validation

Cited by 23 publications

References 33 publications

Study of 3D-printed onyx parts reinforced with continuous glass fibers: Focus on mechanical characterization, analytical prediction and numerical simulation

Study of 3D-printed onyx parts reinforced with continuous glass fibers: Focus on mechanical characterization, analytical prediction and numerical simulation

3D printing continuous natural fiber reinforced polymer composites: A review

Load-Oriented Nonplanar Additive Manufacturing Method for Optimized Continuous Carbon Fiber Parts

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