PSI - Issue 34

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ScienceDirect

Procedia Structural Integrity 34 (2021) 78–86 Structural Integrity Procedia 00 (2019) 000–000 Structural Integrity Procedia 00 (20 9) 000–000

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© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers Abstract By overcoming manufacturing constraints imposed by traditional production technologies, additive manufacturing enables engi neers to realize highly optimized lightweight components of unmatched geometrical complexity. However, the common depen dency of the mechanical material properties on build orientation and wall thickness constitutes a challenge for valid structural analyses of thin-walled parts. Hence within this research, a previously proposed strategy to improve the structural simulations by mapping inhomogeneous material properties into finite shell element models is extended for failure prediction. Therefore, coupons in various build orientations and thicknesses were produced of short fiber-reinforced polyamid 12 via laser sintering and the me chanical properties evaluated by means of digital image correlation-assisted tensile testing. Consequently, the obtained data is utilized for modeling of the thickness dependent and anisotropic material behavior. The inhomogeneous material parameters are automatically mapped in the finite element models and ultimately, numeric simulations are validated by experimental testing of thin-walled parts. The comparisons of finite element analyses with mapped inhomogeneous and conventional constant properties disclosed considerably improved prediction of sti ff ness and failure. For the latter, however, substantial deviations between simula tion and physical experiment remained, indicating that further research is necessary to e ff ectively asses the load bearing capacity of thin-walled additively manufactured structures. 2020 The Authors. Published by Elsevier B.V. is is an open access article under the CC BY- C-ND license (http: // cr ativec mmons.org / licenses / by-nc-nd / 4.0 / ) Peer-review unde responsibility of the scientific committee of the Esi m organisers. Keywords: material modeling; structural finite element analysis; anisotropy; thickness dependency; thin-walled structures; property mapping Considering inhomogeneous material properties for sti ff ness and failure prediction of thin-walled additively manufactured parts Sigfrid-Laurin Sindinger a,b, ∗ , David Marschall c , Christoph Kralovec a , Martin Schagerl a,b a Institute of Structural Lightweight Design, Johannes Kepler University Linz, 4040 Linz, Austria b Christian Doppler Laboratory for Structural Strength Control of Lightweight Constructions, 4040 Linz, Austria c KTM E-TECHNOLOGIES GmbH, 5081 Anif, Austria Abstract By overcoming manufacturing constraints imposed by traditional production technologies, additive manufacturing enables engi neers to realize highly optimized lightweight components of unmatched geometrical complexity. However, the common depen dency of the mechanical material properties on build orientation and wall thickness constitutes a challenge for valid structural analyses of thin-walled parts. Hence within this research, a previously proposed strategy to improve the structural simulations by mapping inhomogeneous material properties into finite shell element models is extended for failure prediction. Therefore, coupons in various build orientations and thicknesses were produced of short fiber-reinforced polyamid 12 via laser sintering and the me chanical properties evaluated by means of digital image correlation-assisted tensile testing. Consequently, the obtained data is utilized for modeling of the thickness dependent and anisotropic material behavior. The inhomogeneous material parameters are automatically mapped in the finite element models and ultimately, numeric simulations are validated by experimental testing of thin-walled parts. The comparisons of finite element analyses with mapped inhomogeneous and conventional constant properties disclosed considerably i proved prediction of sti ff ness and failure. For the latter, however, substantial deviations between simula tion and physical experiment remained, indicating that further research is necessary to e ff ectively asses the load bearing capacity of thin-walled additively manufactured structures. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers. Keywords: material modeling; structural finite element analysis; anisotropy; thickness dependency; thin-walled structures; property mapping The second European Conference on the Structural Integrity of Additively Manufactured Materials Considering inhomogeneous material properties for sti ff ness and failure prediction of thin-walled additively manufactured parts Sigfrid-Laurin Sindinger a,b, ∗ , David Marschall c , Christoph Kralovec a , Martin Schagerl a,b a Institute of Structural Lightweight Design, Johannes Kepler University Linz, 4040 Linz, Austria b Christian Doppler Laboratory for Structural Strength Control of Lightweight Constructions, 4040 Linz, Austria c KTM E-TECHNOLOGIES GmbH, 5081 Anif, Austria The second European Conference on the Structural Integrity of Additively Manufactured Materials

1. Introduction 1. Introduction

Additive manufacturing (AM) enables engineers to realize highly optimized lightweight components of unmatched geometrical complexity. However, the well known anisotropy of the mechanical material properties in combination with their more elusive dependency on wall thickness, constitutes a challenge for valid structural analysis of thin walled structures. The decline of mechanical material properties with decreasing part thickness was reported for Additive manufacturing (AM) enables engineers to realize highly optimized lightweight components of unmatched geometrical complexity. However, the well known anisotropy of the mechanical material properties in combination with their more elusive dependency on wall thickness, constitutes a challenge for valid structural analysis of thin walled structures. The decline of mechanical material properties with decreasing part thickness was reported for

∗ Corresponding author. Tel.: + 43-732-2468-6667. E-mail address: sigfrid-laurin.sindinger@jku.at ∗ Corresponding author. Tel.: + 43-732-2468-6667. E-mail address: sigfrid-laurin.sindinger@jku.at

2452-3216 © 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers 10.1016/j.prostr.2021.12.012 2210-7843 © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers. 2210-7843 © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers.