PSI - Issue 68

Soran Hassanifard et al. / Procedia Structural Integrity 68 (2025) 77–83 S. Hassanifard and K. Behdinan / Structural Integrity Procedia 00 (2025) 000–000

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Fig. 4. Comparison of experimentally obtained fatigue test data with predicted fatigue lives based on (a) modified Morrow, and (b) SWT models.

All the required values were calculated for the 3D-printed composites at both 0º and 90º raster orientations, and, along with the fatigue parameters presented in Table 2, were used for fatigue life predictions. The predicted fatigue lives were then compared with the experimentally obtained fatigue lives. Fig. 4(a) presents the results obtained using the modified Morrow equation, while Fig. 4(b) shows the results from the SWT model. The results reveal that while both models effectively predict the fatigue life of 3D-printed composite samples, the SWT model provides more accurate estimations, with the majority of data points falling within the ±2 scatter bounds. A key advantage of the proposed technique is its ability to be applied to other 3D-printed composites with different UTS values and raster orientations, using only basic static properties of the parts. 4. Conclusion A novel technique has been developed for predicting the fatigue life of 3D-printed ABS/GNP composite parts using modified Morrow and SWT strain-based fatigue damage models. This approach accounts for key factors such as material degradation during cyclic loading, varying raster orientations, and the effects of intrinsic defects commonly found in 3D-printed components. Fatigue strength reduction factors were calculated based on the observation that the fatigue life of 3D-printed samples is typically shorter than that of the neat filament materials. Consequently, the 3D printed samples were modeled as isotropic, homogeneous materials with imaginary notches characterized by specific notch factors. The results demonstrated that while both models were effective, the SWT model provided more accurate predictions of fatigue life for AM composite parts, offering a reliable method for future applications across different raster orientations and GNP contents. Acknowledgements This research was supported by Natural Sciences and Engineering Research Council of Canada (NSERC) under grant RGPIN-217525. The authors are grateful for their support.