Simulation of Displacements and Residual Stresses During the Fabrication of Large, Additively Manufactured, Polymer Parts Using an Efficient Beam Based Approach

  • Hepler, Irja (University of Maine)
  • Davids, William (University of Maine)

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With recent advances, meter-scale structural parts can be fabricated via reinforced polymer large-format additive manufacturing (LFAM). The process utilizes a 3D printer, which deposits molten polymer and is controlled via GCode. The layer-wise nature of the process causes differential cooling which induces deformations and residual stresses, the prediction of which are important for part design. The response of the part can be predicted using a finite element simulation called a sequentially coupled thermomechanical model (SCTM), whereby a heat transfer model of the printing process is run followed by a structural simulation using the resulting temperatures as input. SCTM’s of the LFAM process have been created using 3D continuum elements (eg. [1, 2]) but limiting the element size to the layer height and including enough time steps to accurately capture the printing process can create large models whose computation time can make design space exploration infeasible. Though limited work focuses on computational efficiency, one group derived and applied a novel one-dimensional element based on continuum mechanics [3], and a second study implemented a 2D Euler beam element to simulate 3D printing of a planar wall [4]. In the current work, the model in [4] was improved, extending beam element-based simulation to 3D while maintaining sufficient accuracy and decreasing runtime compared to a continuum model. Euler beam elements represent the beads, while links and linear constraints capture inter-bead force transfer. In addition, a bilinear beam on elastic foundation (BBOEF) element was developed to allow part lift-off without bed penetration. The methodology was applied to the printing of a large wall. Stresses and displacements showed reasonable agreement with continuum model predictions with reduced computation time. Inclusion of the BBOEF element shows the importance of accurately simulating boundary conditions.