Interdependencies between Dynamic Response and Crack Growth in a 3D-Printed Acrylonitrile Butadiene Styrene (ABS) Cantilever Beam under Thermo-Mechanical Loads.

Feiyang He,Muhammad Khan,Salem Aldosari

doi:10.3390/polym14050982

Abstract

Acrylonitrile butadiene styrene (ABS) is the most commonly used thermoplastic printing material for fused deposition modelling (FDM). FDM ABS can be used in a variety of complex working environments. Notably, the thermo-mechanical coupled loads under complex operating conditions may lead to cracking and ultimately catastrophic structural failure. Therefore, it is crucial to determine the crack depth and location before a structural fracture occurs. As these parameters affect the dynamic response of the structure, in this study, the fundamental frequency and displacement amplitude response of a cracked 3D-printed ABS cantilever beam in a thermal environment were analytically and experimentally investigated. The existing analytical model, specifically the torsional spring model used to calculate the fundamental frequency change to determine the crack depth and location was enhanced by the proposed Khan-He model. The analytical relationship between the displacement amplitude and crack was established in Khan-He model and validated for the first time for FDM ABS. The results show that a reduced crack depth and location farther from the fixed end correspond to a higher fundamental frequency and displacement amplitude. An elevated ambient temperature decreases the global elastic modulus of the cracked beam and results in a lower fundamental frequency. Moreover, a non-monotonic relationship exists between the displacement amplitude and ambient temperature. The displacement amplitude is more sensitive to the crack change than the fundamental frequency in the initial stages of crack growth.

Highlights

Fused deposited modelling (FDM) is used in 3D-printed plastic products extensively.It refers to heat thermoplastic materials, extrudes filaments from the nozzle and deposits on growing works layer-by-layer [1]
The National Aeronautics and Space Administration (NASA) launched an FDM CubeSat Trailblazer in November 2013 to demonstrate its durability in extreme environments [4]
Some research discussed the applications of FDM Acrylonitrile butadiene styrene (ABS) models for wind tunnel testing

Summary

Introduction

Fused deposited modelling (FDM) is used in 3D-printed plastic products extensively. It refers to heat thermoplastic materials, extrudes filaments from the nozzle and deposits on growing works layer-by-layer [1]. FDM is gaining widespread attention from industry and academic research. Long et al introduced the FDM for biomedical and pharmaceutical applications. Espalin et al reported FDM device applications in the next-generation space exploration vehicle. Some research discussed the applications of FDM ABS models for wind tunnel testing. The research results showed relatively good agreement between FDM and conventional manufactured models. The FDM model can replace metal to measure aerodynamic characteristics and verify aerodynamic data obtained in the aerospace industry, even at transonic speeds. The FDM model can replace metal to measure aerodynamic characteristics and verify aerodynamic data obtained in the aerospace industry, even at transonic speeds. [5,6]

Methods

Results

Conclusion