Abstract
Additive manufacturing develops rapidly, especially, fused deposition modeling (FDM) is one of the economical methods with moderate tolerances and high design flexibility. Ample studies are being undertaken for modeling the mechanical characteristics of FDM by using the Finite Element Method (FEM). Even in use of amorphous materials, FDM creates anisotropic structures effected by the chosen manufacturing parameters. In order to investigate these process-related characteristics and tailored properties of FDM structures, we prepare FDM-printed poly(ethylene terephthalate) glycol (PETG) samples with different process parameters. Mechanical and optical characterizations are carried out. We develop 2D-digital-image-correlation code with machine learning algorithm, namely K-means cluster, to analyze microstructures (contact surfaces, the changes in fiber shapes) and calculate porosity. By incorporating these characteristics, we draw CAD images. A digital twin of mechanical laboratory tests are realized by the FEM. We use computational homogenization approach for obtaining the effective properties of the FDM-related anisotropic structure. These simulations are validated by experimental characterizations. In this regard, a systematic methodology is presented for acquiring the anisotropy from the process related inner substructure (microscale) to the material response at the homogenized length scale (macroscale). We found out that the layer thickness and overlap ratio parameters significantly alter the microstructures and thereby, stiffness of the macroscale properties.Graphical
Highlights
Additive manufacturing methods are frequently and increasingly employed manufacturing techniques of the 21st century [1,2,3,4,5]
Among them, Fused Deposition Modeling (FDM) technique has been developed in the 1980s, and it is seen as a new candidate next to the conventional manufacturing methods such as turning, grinding, milling, casting, etc. [10]
We experimentally examine the effect of overlap and layer thickness in FDM poly(ethylene terephthalate) glycol (PETG)
Summary
Additive manufacturing methods are frequently and increasingly employed manufacturing techniques of the 21st century [1,2,3,4,5]. Design freedom makes FDM adequate for industries, where complex parts [11,12,13,14,15] are needed among others in aerospace, biomedical [16] automotive, aeronautics, biomechanical [17, 18] as well as research [19,20,21,22,23] especially for studying metamaterials [24,25,26,27]. Mechanical response must be predicted in the design phase [28,29,30]
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