Due to the continuous development of material extrusion-additive manufacturing (MEX-AM) technology, the fracture behavior of polymeric parts, and especially of their associated composites, presents some shortcomings but also a challenge in the field. In this paper, the fracture properties of non-reinforced (NR) and reinforced Polylactic Acid (PLA) samples manufactured by MEX-AM process are investigated through tensile, flexural and fracture mechanics tests. The samples are reinforced with glass fibers (GF-PLA), carbon fibers (CF-PLA) and bronze particles (BP-PLA), and tested parallel (named FLAT for all tests) and normal (named UPRIGHT for tensile test, and ON-EDGE for flexural and fracture mechanics tests) to the layer growth (LG). It was found that regardless of the type of test, the LG and the material significantly influence the mechanical properties and collapse modes of the MEX-printed samples. It was obtained that the parallel-LG load is favorable for the tensile and flexural tests, and the normal-LG for the fracture mechanics tests. Overall, the NR-PLA material gives the best strength, strain and energy absorption properties, CF-PLA stands out as the stiffest material, while BP-PLA presents the minimum performances for almost all properties. The macroscopic analyzes of the fractured samples clearly highlight distinct failure mechanisms associated with each type of test, material and LG. From the analysis of the mechanical behavior and macrostructural images, CF-PLA was identified as the most brittle material, and NR-PLA the most ductile. 

Tensile, flexural and fracture properties of MEX-printed PLA-based composites

Mechanical strength of 3D-printed components dramatically depends on printing process parameters. These can be usually set over a relatively wide range, in combinations that determine the microstructure morphology and the resulting mechanical behaviour. The present investigation focuses on the relationship between revealed structure and resulting mechanical properties of FDM-printed ABS specimens. The peculiar structures, examined at the meso- and microscale, are modelled by a finite-element Representative Volume Element (RVE) approach, in conjunction with cohesive elements to reproduce the sealing efficiency between fused filaments. The simulation of the tensile response up to failure falls within the 95% of confidence with experiments. Also, homogenized response of RVE determines spatial material constants useful for the effective numerical simulations of functional components, and intra- and inter-layer damage mechanisms are distinguished providing hints for the structural optimization. 

Combined RVE-Cohesive elements approach to the multi-scale modelling of FDM 3D-printed components

Purpose Finite element (FE) analysis can be used for both design and verification of components. In the case of 3D-printed materials, a proper characterization of properties, accounting for anisotropy and raster angles, can help develop efficient material models. This study aims to use compression tests to characterize short carbon-reinforced PA12 made by fused filament fabrication (FFF) and to model its behaviour by the FE method. Design/methodology/approach In this work, the authors focus on compression tests, using post-processed specimens to overcome external defects introduced by the FFF process. The material’s elastoplastic mechanical behaviour is modelled by an elastic stiffness matrix, Hill’s anisotropic yield criterion and Voce’s isotropic hardening law, considering the stacking sequence of raster angles. A FE analysis is conducted to reproduce the material’s compressive behaviour through the LS-DYNA software. Findings The proposed model can capture stress values at different deformation levels and peculiar aspects of deformed shapes until the onset of damage mechanisms. Deformation and damage mechanisms are strictly correlated to orientation and raster angle. Originality/value The paper aims to contribute to the understanding of 3D-printed material’s behaviour through compression tests on bulk 3D-printed material. The methodology proposed, enriched with an anisotropic damage criterion, could be effectively used for design and verification purposes in the field of 3D-printed components through FE analysis. 

pdf/effects-of-anisotropy-and-infill-pattern-on-compression-2vtssr4uqw.pdf

Effects of anisotropy and infill pattern on compression properties of 3D printed CFRP: mechanical analysis and elasto-plastic finite element modelling

Experiment and numerical investigation on beetle elytra inspired lattice structure: enhanced mechanical properties and customizable responses

Influence of process parameters on temperature field and residual strain in FFF-printed parts

The choice of the optimal printing setup for Fused Deposition Modeling (FDM) 3D-printing technology is challenging due to complex interactions between process parameters and mechanical properties. This especially affects engineering applications where the maximum performance is required. To address this challenge, this study explores the influence of main controllable printing parameters including layer thickness, extrusion temperature, printing speed and deposition patterns, on the mechanical properties of FDM-printed ABS specimens using the Design-of-Experiments (DoE) approach by a 34\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$3^4$$\end{document} full factorial design. Main-effects and Interaction-effects on tensile strength, elastic modulus, and strain at maximum stress are investigated via ANOVA analysis, providing interesting hints to evaluate at the design stage. Given the complexity of these effects, a deeper investigation is conducted with a quadratic regression model of the Response Surface Method and the Random Forest regressor, with the latter enhancing the predictive capability (R2\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$R^2$$\end{document}) on test data by more than 40% for all the mechanical properties. Eventually, a Genetic Algorithm (NSGA-II) is integrated to estimate the optimal parameter set for multiple responses. Overall results indicate that the deposition strategy is the parameter affecting the most the overall mechanical response, with “Lines” pattern providing the best balanced results in maximizing the elastic modulus and the tensile strength, respectively 1381 MPa and 33.3 MPa. Testing of a set of specimens printed with the found optimal parameters confirm the model’s prediction.

Multi objective optimization of FDM 3D printing parameters set via design of experiments and machine learning algorithms

Analysis and modelling of damage mechanism in FDM 3D-printed lattice structure under compression loading

Knowledge of the effective slip strength is a crucial safety issue when a bolted connection is designed to work by friction. Even if technical standards indicate the necessary tightening torque to obtain the desired preload, experimental relationship between bolt torque and preload is required in many cases where surface and bolt conditions are uncertain. In this work, the torque–preload relationship and the effective slip factors of bolted joints operating under non-standard surface conditions, namely COR-TEN and Zn-coated plates, are determined experimentally, and compared with standard as-rolled data. Results indicate that the requirements of design standards are not always conservative, making experimental characterization of the joint necessary. 

Slip strength of COR-TEN and Zn-coated steel preloaded bolted joints

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