Flexural behavior of additively manufactured Ultem 1010: experiment and simulation

Abstract

Purpose The purpose of this paper is to study the flexural behavior of additively manufacture Ultem 1010 parts. Fused deposition modeling (FDM) process has become one of most widely used additive manufacturing methods. The process provides the capability of fabricating complicated shapes through the extrusion of plastics onto a print surface in a layer-by-layer structure to build three-dimensional parts. The flexural behavior of FDM parts are critical for the evaluation and optimization of both material and process. Design/methodology/approach This study focuses on the performance of FDM solid and sparse-build Ultem 1010 specimens. Flexure tests (three-point bend) are performed on solid-build coupons with varying build orientation and raster angle. These parameters are investigated through a full-factorial design of experiments (DOE) to determine optimal build parameters. Air gap, raster width and contour width are held constant. A three-dimensional nonlinear finite element model is built to simulate the flexural behavior of the FDM parts. Findings Experimental results include flexure properties such as yield strength and modulus, as well as analysis of the effect of change in build parameters on material properties. The sparse-build FDM parts chosen from the experimental tests are simulated based on this developed model. Thermo-mechanical simulation results show that the finite element simulation and experimental tests are in good agreement. The simulation can be further extended to other complicated FDM parts. Originality/value From the DOE study, sparse-build coupons with specific build parameters are fabricated and tested for the validation of a finite element simulation.

Fused deposition modelling: a review

“…Gomez-Gras et al (2018) observed that fill density was the most prominent process parameter followed by nozzle diameter and layer thickness on fatigue life. Taylor et al (2018) studied the consequence of build orientation and raster angle on flexural strength of parts made of ULTEM 1010 (unfilled polyetherimide – a semi-transparent high strength material) material experimentally and numerically. Gebisa and Lemu (2018) found that the raster width and raster angle had the maximum effect on the flexural properties of ULTEM 9085 components.…”

Basalt Fiber Composites with Reduced Thermal Expansion for Additive Manufacturing

“…The use of these strategies has reported improvements in the mechanical properties of the composites. For instance, Taylor et al used atmospheric plasma to increase the adhesion of BF to a PP matrix processed by FFF and increasing its flexural modulus by 12% [ 39 ].…”

Extrusion Additive Manufacturing of PEI Pellets

“…Motaparti and her colleagues [23] studied the relationship between build direction, raster angle of the filling, and air gap with compression properties at different temperatures on ULTEM™ 9085 parts produced by filament AM. Taylor and his colleagues, in 2018, carried on Motaparti's research by producing ULTEM™ 1010 specimens with varying raster angles and building direction to evaluate how these parameters would affect flexural properties [24]. They developed a simulation of the flexural experiment and validated it with the performed tests.…”