Title: Prediction of Mechanical Properties of Additively Manufactured Discontinuous Fiber Composites Accounting for Defects and Uncertainties

Authors: Harsh Baid, Reza Hajiha, and Frank Abdi

DOI: 10.33599/nasampe/c.19.0784

Abstract: Carbon fiber-containing ABS resin feedstock fabricated using FDM process at different fiber loadings were analyzed. It was observed that as the fiber loadings were increase there was no significant increase in the material performance as well as it also exhibits scatter in modulus and strength. Significant porosity were observed in FDM-printed samples and with increasing fiber content, voids inside the FDM-printed beads increased, while voids between the beads decreased. Furthermore, SEM micrographs show that fibers had pulled out of the matrix, indicating weak interfacial adhesion between the fibers and the matrix. Objective: Implement Integrated Computational Material Engineering (ICME) approach to computationally predict additively manufactured discontinuous fiber composite mechanical properties considering various effects of manufacturing defects and uncertainty. Methodology: The methodology is based on dehomogenized nano-micro multi-scale modeling approach. Validation: Mechanical properties (strength and modulus) of Acrylonitrile butadiene styrene (ABS) copolymer (GP35-ABS-NT) reinforced with short discontinuous Carbon Fiber (CF) is predicted as a function of fiber length and fiber content. The predicted results are in good agreement with experiments. Effect of manufacturing defects such as voids (e.g., shape/size/distribution) and the role of the fiber/matrix interface were also considered and were varied for different fiber contents. Reliability, sensitivity and allowables of the material were also verified against the range of scatter observed in test resulting from AM process. The developed reverse engineering approach is used to predict fiber orientation through thickness and was validated with test.

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Conference: CAMX 2019

Publication Date: 2019/09/23

SKU: TP19-0784

Pages: 10

Price: $20.00