Experimental characterization, theoretical modeling and failure analysis of the mechanical behavior of acrylonitrile butadiene styrene parts by fused filament fabrication
ISSN: 1355-2546
Article publication date: 3 October 2023
Issue publication date: 2 January 2024
Abstract
Purpose
The purpose of this research is present an experimental and numerical study of the mechanical properties of the acrylonitrile butadiene styrene (ABS) in the additive manufacturing (AM) by fused filament fabrication (FFF). The characterization and mechanical models obtained are used to predict the elastic behavior of a prosthetic foot and the failure of a prosthetic knee manufactured with FFF.
Design/methodology/approach
Tension tests were carried out and the elastic modulus, yield stress and tensile strength were evaluated for different material directions. The material elastic constants were determined and the influence of infill density in the mechanical strength was evaluated. Yield surfaces and failure criteria were generated from the tests. Failures over prosthetic elements in tridimensional stresses were analyzed; the cases were evaluated via finite element method.
Findings
The experimental results show that the material is transversely isotropic. The elasticity modulus, yield stress and ultimate tensile strength vary linearly with the infill density. The stresses and the failure criteria were computed and compared with the experimental tests with good agreement.
Practical implications
This research can be applied to predict failures and improve reliability in FFF or fused deposition modeling (FDM) products for applications in high-performance industries such as aerospace, automotive and medical.
Social implications
This research aims to promote its widespread adoption in the industrial and medical sectors by increasing reliability in products manufactured with AM based on the failure criterion.
Originality/value
Most of the models studied apply to plane stress situations and standardized specimens of printed material. However, the models applied in this study can be used for functional parts and three-dimensional stress, with accuracy in the range of that obtained by other researchers. The researchers also proposed a method for the mechanical study of fragile materials fabricated by processes of FFF and FDM.
Keywords
Acknowledgements
The authors acknowledge William Fuentes for his advice during the Continuous Media Mechanics course of the PhD in Mechanical Engineering of the Universidad del Norte.
This work was supported by Universidad del Atlántico calls RES001735 13 OCT. 2016 and RES002087 22 DEC. 2016, the experimental data was obtained in the Universidad del Norte, Universidad del Atlántico, and 3D Ingenieria Bq SAS.
Since acceptance of this article, the following author have updated their affiliations: Roberto Junior Algarín Roncallo is at the Department of Mechanical Engineering, Universidad del Atlantico, Barranquilla, Colombia.
Citation
Algarín Roncallo, R.J., Lopez Taborda, L.L. and Guillen, D. (2024), "Experimental characterization, theoretical modeling and failure analysis of the mechanical behavior of acrylonitrile butadiene styrene parts by fused filament fabrication", Rapid Prototyping Journal, Vol. 30 No. 1, pp. 145-160. https://doi.org/10.1108/RPJ-03-2023-0097
Publisher
:Emerald Publishing Limited
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