Annual Book Of Astm Standards

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments.

The increase in accessibility of fused filament fabrication (FFF) machines has inspired the scientific community to work towards the understanding of the structural performance of components fabricated with this technology. Numerous attempts to characterize and to estimate the mechanical properties of structures fabricated with FFF have been reported in the literature. Experimental characterization of printed components has been reported extensively. However, few attempts have been made to predict properties of printed structures with computational models, and a lot less work with analytical approximations. As a result, a thorough review of reported experimental characterization and predictive models is presented with the aim of summarizing applicability and limitations of those approaches. Finally, recommendations on practices for characterizing printed materials are given and areas that deserve further research are proposed.

https://www.mdpi.com/1996-1944/12/6/895/pdf

Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches

The aim of this paper is to investigate the dynamic behavior of singly and doubly-curved panels reinforced by curvilinear fibers. The Variable Angle Tow (VAT) technology allows the placement of fibers along curvilinear paths with the purpose of improving dynamic performance of plates and shells. The effect of the variation of constants which define analytically the fiber orientation is also investigated by several parametric studies. The Carrera Unified Formulation (CUF) with different thickness functions along the three orthogonal curvilinear directions is the basis of the present theoretical model. Various doubly-curved laminated panels reinforced by curvilinear fibers are analyzed using several structural theories. The Local Generalized Differential Quadrature (LGDQ) method is employed to solve numerically free vibration problems. Compared to the well-known GDQ method from which it descends, the LGDQ is characterized by banded matrices instead of full ones, since the current technique considers only few points of the whole domain. Therefore, the solution of the equation system needs a lower computational effort.

Higher-order theories for the free vibrations of doubly-curved laminated panels with curvilinear reinforcing fibers by means of a local version of the GDQ method

The main aim of the present paper is to solve numerically the free vibration problem of sandwich shell structures with variable thickness and made of Functionally Graded Materials (FGMs). Several Higher-order Shear Deformation Theories (HSDTs), defined by a unified formulation, are employed in the study. The FGM structures are characterized by variable mechanical properties due to the through-the-thickness variation of the volume fraction distribution of the two constituents and the arbitrary thickness profile. A four-parameter power law expression is introduced to describe the FGMs, whereas general relations are used to define the thickness variation, which can affect both the principal coordinates of the shell reference domain. A local scheme of the Generalized Differential Quadrature (GDQ) method is employed as numerical tool. The natural frequencies are obtained varying the exponent of the volume fraction distributions using higher-order theories based on a unified formulation. The structural models considered are two-dimensional and require less degrees of freedom when compared to the corresponding three-dimensional finite element (FE) models, which require a huge number of elements to describe the same geometries accurately. A comparison of the present results with the FE solutions is carried out for the isotropic cases only, whereas the numerical results available in the literature are used to prove the validity as well as accuracy of the current approach in dealing with FGM structures characterized by a variable thickness profile.

/pdf/a-numerical-investigation-on-the-natural-frequencies-of-fgm-32kkxkmbn1.pdf

A Numerical Investigation on the Natural Frequencies of FGM Sandwich Shells with Variable Thickness by the Local Generalized Differential Quadrature Method

Abstract The paper proposes a comparison between classical two-dimensional (2D) finite elements (FEs) and an exact three-dimensional (3D) solution for the free vibration analysis of one-layered and multilayered isotropic, composite and sandwich plates and cylinders. Low and high order frequencies are analyzed for thick and thin simply supported structures. Vibration modes are investigated to make a comparison between results obtained via the finite element method and those obtained by means of the exact three-dimensional solution. The 3D exact solution is based on the differential equations of equilibrium written in general orthogonal curvilinear coordinates. This exact method is based on a layer-wise approach, the continuity of displacements and transverse shear/normal stresses is imposed at the interfaces between the layers of the structure. The geometry for shells is considered without any simplifications. The 2D finite element results are obtained by means of a well-known commercial FE code. The differences between 2D FE solutions and 3D exact solutions depend on the considered mode, the order of frequency, the thickness ratio of the structure, the geometry, the embedded material and the lamination sequence.

Exact 3D solutions and finite element 2D models for free vibration analysis of plates and cylinders

Abstract Desktop 3D FDM (Fused Deposition Modelling) printers are usually employed for the production of nonstructural objects. In recent years, the present authors tried to use this technology also to produce structural elements employed in the construction of small UAVs (Unmanned Aerial Vehicles). Mechanical stresses are not excessive for small multirotor UAVs. Therefore, the FDM technique combined with polymers, such as the ABS (Acrylonitrile Butadiene Styrene) and the PLA(Poly Lactic Acid), can be successfully employed to produce structural components. The present new work is devoted to the production and preliminary structural analysis of sandwich configurations. These new lamination schemes could lead to an important weight reduction without significant decreases of mechanical properties. Therefore, it could be possible, for the designed application (e.g., a multifunctional small UAV produced via FDM), to have stiffener and lighter structures easy to be manufactured with a low-cost 3D printer. The new sandwich specimens here proposed are PLA sandwich specimens embedding a PLA honeycomb core produced by means of the same extruder, multilayered specimens with ABS external layers and an internal homogeneous PLA core using different extruders for the two materials, sandwich specimens with external ABS skins and an internal PLA honeycomb core using different extruders for the two materials, and sandwich specimens where two different extruders have been employed for PLA material used for skins and for the internal honeycomb core. For all the proposed configurations, a detailed description of the production activity is given.Moreover, several preliminary results about three-point bending tests, different mechanical behaviors and relative delamination problems for each sandwich configuration will be discussed in depth.

3D FDM production and mechanical behavior of polymeric sandwich specimens embedding classical and honeycomb cores

In this paper, polymeric specimens are produced via the Fused Deposition Modelling (FDM) technique. Then, experimental tensile and compression tests are conducted to evaluate the main mechanical properties of elements made of PolyLacticAcid (PLA) material. A standardized characterization test method for FDM 3D printed polymers has not been developed yet. For this reason, the ASTM D695 (usually employed for polymers produced via classical methods) has been here employed for FDM 3D printed polymers after opportune modifications suggested by appropriate experimental checks. A statistical analysis is performed on the geometrical data of the specimens to evaluate the machine process employed for the 3D printing. A capability analysis is also conducted on the mechanical properties (obtained from the experimental tests) in order to calculate acceptable limits useful for possible structural analyses. The Young modulus, the proportional limit and the maximum strength here defined for PLA specimens allow to confirm the different behavior of FDM printed PLA material in tensile and compressive state. These differences and the calculated acceptable limits for the found mechanical properties must be considered when this technology will be employed for the design of small structural objects made of PLA, as in the present study, or ABS (Acrilonitrile Butadiene Stirene). From the statistical and capability analysis, the employed printing process appears as quite stable and replicable. These types of research together with other similar ones that will be conducted in the future will allow to use polymeric materials and the FDM technique to produce small structural elements and also to carry out the appropriate verifications.

https://www.mdpi.com/2504-477X/4/3/140/pdf

Tensile and Compressive Behavior in the Experimental Tests for PLA Specimens Produced via Fused Deposition Modelling Technique

Additive manufacturing has introduced a great step in the manufacturing process of consumer goods. Fused Deposition Modeling (FDM) and in particular 3D printers for home desktop applications are employed in the construction of prototypes, models and in general in non-structural objects. The aim of this new work is to characterize this process in order to apply this technology in the construction of aeronautical structural parts when stresses are not excessive. An example is the construction of the PoliDrone UAV, a multicopter patented, designed and realized by researchers at Politecnico di Torino. For this purpose, a statistical characterization of the mechanical properties of ABS (Acrylonitrile Butadiene Styrene) specimens in compression tests is proposed in analogy with the past authors’ work about the tensile characterization of ABS specimens. A desktop 3D printer, including ABS filaments as the material, has been employed. ASTM 625 has been considered as the reference normative. A capability analysis has also been used as a reference method to evaluate the boundaries of acceptance for both mechanical and dimensional performances. The statistical characterization and the capability analysis are here proposed in an extensive form in order to validate a general method that will be used for further tests in a wider context.

https://www.mdpi.com/2227-7080/5/2/20/pdf

Compression Tests of ABS Specimens for UAV Components Produced via the FDM Technique

In this work, the behaviour of short-length PLA 3D printed elements under compression is investigated, with a specific focus on buckling. An extensive experimental campaign is conducted on square polymeric columns produced via Fused Filament Fabrication (FFF), with the longitudinal axis oriented in the out-of-plane direction in 3D printing coordinate system. Compressive and tensile mechanical properties of FFF 3D printed PLA are determined; an asymmetry in out-of-plane tensile-compressive behaviour is discussed. The compression of the specimens is monitored using a single camera Digital Image Correlation system, supported by a preliminary validation of its set-up. The slenderness ratio at which the elements start to buckle is identified. The experimental results are compared with three analytical models for buckling prediction in isotropic materials and with linear and non-linear Finite Elements (FE) models. For a broad range of slenderness ratio, the tangent modulus theory gave a good, if conservative, estimation of the critical loads when used with the compressive mechanical properties. Furthermore, the predictions of the non-linear FE models were found to be consistent with the experimental results.

Roberto Torre

Papers

Exact 3D solutions and finite element 2D models for free vibration analysis of plates and cylinders

3D FDM production and mechanical behavior of polymeric sandwich specimens embedding classical and honeycomb cores

Tensile and Compressive Behavior in the Experimental Tests for PLA Specimens Produced via Fused Deposition Modelling Technique

Compression Tests of ABS Specimens for UAV Components Produced via the FDM Technique

Buckling developed in 3D printed PLA cuboidal samples under compression: Analytical, numerical and experimental investigations