Additive Manufacturing of Composite Polymers: Thermomechanical FEA and Experimental Study

被引:16
作者
Behseresht, Saeed [1 ]
Park, Young Ho [1 ]
机构
[1] New Mexico State Univ, Dept Mech & Aerosp Engn, Las Cruces, NM 88003 USA
基金
英国科研创新办公室;
关键词
additive manufacturing; FEA; user subroutine; fused deposition modeling; composite polymers; FUSED FILAMENT FABRICATION; RESIDUAL-STRESS; TEMPERATURE; SIMULATION; CRYSTALLIZATION; PREDICTION; PART;
D O I
10.3390/ma17081912
中图分类号
O64 [物理化学(理论化学)、化学物理学];
学科分类号
070304 ; 081704 ;
摘要
This study presents a comprehensive approach for simulating the additive manufacturing process of semi-crystalline composite polymers using Fused Deposition Modeling (FDM). By combining thermomechanical Finite Element Analysis (FEA) with experimental validation, our main objective is to comprehend and model the complex behaviors of 50 wt.% carbon fiber-reinforced Polyphenylene Sulfide (CF PPS) during FDM printing. The simulations of the FDM process encompass various theoretical aspects, including heat transfer, orthotropic thermal properties, thermal dissipation mechanisms, polymer crystallization, anisotropic viscoelasticity, and material shrinkage. We utilize Abaqus user subroutines such as UMATHT for thermal orthotropic constitutive behavior, UEPACTIVATIONVOL for progressive activation of elements, and ORIENT for material orientation. Mechanical behavior is characterized using a Maxwell model for viscoelastic materials, incorporating a dual non-isothermal crystallization kinetics model within the UMAT subroutine. Our approach is validated by comparing nodal temperature distributions obtained from both the Abaqus built-in AM Modeler and our user subroutines, showing close agreement and demonstrating the effectiveness of our simulation methods. Experimental verification further confirms the accuracy of our simulation techniques. The mechanical analysis investigates residual stresses and distortions, with particular emphasis on the critical transverse in-plane stress component. This study offers valuable insights into accurately simulating thermomechanical behaviors in additive manufacturing of composite polymers.
引用
收藏
页数:21
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