Research Papers

Analysis and Numerical Simulation of the Structural Performance of Fused Deposition Modeling Samples With Variable Infill Values

[+] Author and Article Information
Steffany N. Cerda-Avila

Facultad de Ingeniería,
Universidad Autonoma de San Luis Potosí,
San Luis Potosí 78290, México
e-mail: steffany.noemi@gmail.com

Hugo I. Medellín-Castillo

Facultad de Ingeniería,
Universidad Autonoma de San Luis Potosí,
San Luis Potosí 78290, México
e-mail: hugoivanmc@uaslp.mx

Dirk F. de Lange

Facultad de Ingeniería,
Universidad Autonoma de San Luis Potosí,
San Luis Potosí 78290, México
e-mail: dirk.delange@uaslp.mx

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received September 15, 2017; final manuscript received September 6, 2018; published online December 20, 2018. Assoc. Editor: Erdogan Madenci.

J. Eng. Mater. Technol 141(2), 021005 (Dec 20, 2018) (7 pages) Paper No: MATS-17-1270; doi: 10.1115/1.4041854 History: Received September 15, 2017; Revised September 06, 2018

The prediction of the structural performance of additive manufacturing (AM) parts has become one of the main challenges to boost the use of AM in industry. The structural properties of AM are very important in order to design and fabricate parts not only of any geometrical shape but also with variable or customized mechanical properties. While AM experimental studies are common in the literature, a limited number of investigations have focused on the analysis and prediction of the mechanical properties of AM parts using theoretical and numerical approaches, such as the finite element method (FEM); however, their results have been not accurate yet. Thus, more research work is needed in order to develop reliable prediction models able to estimate the mechanical performance of AM parts before fabrication. In this paper, the analysis and numerical simulation of the structural performance of fused deposition modeling (FDM) samples with variable infill values is presented. The aim is to predict the mechanical performance of FDM components using numerical models. Thus, several standard tensile test specimens were fabricated in an FDM system using different infill values, a constant layer thickness, one shell perimeter, and polylactic acid (PLA) material. These samples were measured and modeled in a computer-aided design (CAD) system before performing the experimental tensile tests. Numerical models and simulations based on the FEM method were then developed and carried out in order to predict the structural performance of the specimens. Finally, the experimental and numerical results were compared and conclusions drawn.

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Fig. 2

Type I for tensile test specimens [11]

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Fig. 3

Tensile test of one specimen

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Fig. 4

Microstructures and porosity of the real FDM test specimens (left) and CAD specimens (right): (a) 37% infill, (b) 37.58% infill, (c) 54% infill, (d) 65.70% infill, (e) 82% infill, and (f) 96.61% infill

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Fig. 5

Finite element method models: (a) 37.58% infill specimen, 536 978 elements, (b) 65.70% infill specimen, 588 291 elements, and (c) 96.61% infill specimen, 705 377 elements

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Fig. 6

Finite element method boundary conditions

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Fig. 7

Equivalent elastic modulus versus infill percentage



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