Comparison of FEA simulations and experimental results for as-built additively manufactured dogbone specimens

Prathamesh Baikerikar,Cameron J Turner

doi:10.1007/s00170-021-07307-9

Prathamesh Baikerikar, Cameron J Turner

Open Access

https://doi.org/10.1007/s00170-021-07307-9

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Abstract

Parts built using fused deposition modeling (FDM—an additive manufacturing technology) differ from their design model in terms of their microstructure and material properties. These differences lead to a certain amount of ambiguity regarding the structure, strength, and stiffness of the final FDM part. Increasing use of FDM parts as end use products necessitates accurate simulations and analyses during part design. However, analysis methods such as finite element analysis, are used for analysis of continuum models, and may not accurately represent the non-continuous non-linear FDM parts. Therefore, it is necessary to determine the accuracy and precision of FEA for FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. Dogbone geometries that include different infill patterns are tested under tensile loading and later simulated using FEA. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

Highlights

In the recent years, engineering and manufacturing sectors have shown an increasing interest in Additive Manufacturing (AM) or 3D printing as a means of manufacturing
This study found that Finite Element Analysis (FEA) results are not always an accurate or reliable means of predicting Fused Deposition Modeling (FDM) part behaviors
The aim of this study is to evaluate and compare approaches to correlate the FDM parts analyzed in FEA with corresponding experimental results

Summary

Introduction

In the recent years, engineering and manufacturing sectors have shown an increasing interest in Additive Manufacturing (AM) or 3D printing as a means of manufacturing. The extruder of the 3D printer follows this G-code and builds the model from bottom-up by depositing material along geometry of the part on the printer bed. It does this by heating the plastic filament to a semi-molten state and feeding it through the extruder nozzle. This kind of additive technique enables one to build complex geometries with relative ease, while eliminating the need for assembling complex parts from simple components. The FDM software, defines a solid continuous model with an infill pattern with a sufficiently thick perimeter and a porous infill to save weight With more research, these infill patterns can be used for function specific purposes as well

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