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The effect of process parameters on the mechanical properties of additively manufactured parts using a hierarchical multiscale model

Taha Sheikh (Advanced Research Laboratory for Multifunctional Lightweight Structures (ARL-MLS), Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, Canada)
Kamran Behdinan (Advanced Research Laboratory for Multifunctional Lightweight Structures (ARL-MLS), Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, Canada)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 15 December 2022

27

Abstract

Purpose

This paper aims to present a hierarchical multiscale model to evaluate the effect of fused deposition modeling (FDM) process parameters on mechanical properties. Asymptotic homogenization mathematical theory is developed into two scales (micro and macro scales) to compute the effective elastic and shear modulus of the printed parts. Four parameters, namely, raster orientation, layer height, build orientation and porosity are studied.

Design/methodology/approach

The representative volume elements (RVEs) are generated by mimicking the microstructure of the printed parts. The RVEs subjected to periodic boundary conditions were solved using finite element. The experimental characterization according to ASTM D638 was conducted to validate the computational modeling results.

Findings

The computational model reports reduction (E1, ∼>38%) and (G12, ∼>50%) when porosity increased. The elastic modulus increases (1.31%–47.68%) increasing the orthotropic behavior in parts. Quasi-solids parts (100% infill) possess 10.71% voids. A reduction of 11.5% and 16.5% in elastic modulus with layer height is reported. In total, 45–450 oriented parts were highly orthotropic, and 0–00 parts were strongest. The order of parameters affecting the mechanical properties is porosity > layer height > raster orientation > build orientation.

Originality/value

This study adds value to the state-of-the-art terms of construction of RVEs using slicing software, discarding the necessity of image processing and study of porosity in FDM parts, reporting that the infill density is not the only measure of porosity in these parts.

Keywords

Acknowledgements

Declaration of competing interests: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

The funding received for this research from The National Science and Engineering Research Council of Canada (NSERC under grant RGPIN-217525) as well as the support from the Advanced Research Laboratory Multifunctional Lightweight Structures (ARL-MLS), University of Toronto, is greatly acknowledged.

Citation

Sheikh, T. and Behdinan, K. (2022), "The effect of process parameters on the mechanical properties of additively manufactured parts using a hierarchical multiscale model", Rapid Prototyping Journal, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/RPJ-08-2022-0248

Publisher

:

Emerald Publishing Limited

Copyright © 2022, Emerald Publishing Limited

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