Title: MODELING OF MICROSTRUCTURAL IRREGULARITIES IN ADDITIVELY MANUFACTURED CONTINUOUS FIBER-REINFORCED POLYMERS
Authors: Yuri Nikishkov, Guillaume Seon, Brian Shonkwiler, Andrew Makeev
Abstract: The additive manufacturing (AM) process often produces parts with AM-specific microstructural irregularities. Example defects include voids, geometric errors, pathing errors, and variability of individual layers. Inherent susceptibility to these defects contributes to higher variability of part quality than found in parts manufactured using a traditional manufacturing process. The presence of microstructural defects at critical locations may significantly reduce strength and useful life of additively manufactured structures. Using continuous carbon fiber reinforced thermoplastics (CFRTPs) for primary structures is the newest and rapidly growing area in AM with adequate fiber volumes (50-60%) recently achieved. The manufacturing process deposits filaments that consist of continuous standard aerospace grade carbon fibers. Far more significant complexity of material microstructure including inherent discontinuities and defects have been observed in AM composite parts compared to metal structures. In this work, we present a Finite Element Modeling (FEM) framework that captures filament-level defects in as-manufactured CFRTP laminates. High-fidelity FE models are automatically generated from X-ray CT scans of CFRTP specimens and used for building complete filament-level models or representative volume element analysis. Novel ply segmentation method based on autocorrelation of fiber patterns efficiently detects filament waviness. FEM results are compared with experiments for box-beam test specimens.
References: 1. Frazier, W. “Metal Additive Manufacturing: A Review”. Journal of Materials Engineering and Performance 23 (2014): 1917-1928. 2. Kim, F. and Moylan, S. “Literature Review of Metal Additive Manufacturing Defects”, NIST Advanced Manufacturing Series 100 (2018): 16. 3. ABAQUS 2020 User’s Manual. Dassault Systèmes Simulia Corp.: Pawtucket, RI, USA, 2020. 4. Nikishkov, Y., Nikishkov, G., Seon, G., Shonkwiler, B., Makeev, A., Schaefer, J.D. and Justusson, B. “Structures Technology for Component Damage and Failure Prediction”, Journal of the American Helicopter Society, 66 (2021): 032006. 5. Makeev, A., Seon, G., Nikishkov, Y., Nguyen, D., Mathews, P. and Robeson, M. “Analysis Methods Improving Confidence in Material Qualification for Laminated Composites”, Journal of the American Helicopter Society, 64 (2019): 012006. 6. Makeev, A., He, Y., Carpentier, P. and Shonkwiler, B. “A Method for Measurement of Multiple Constitutive Properties for Composite Materials”. Composites: Part A 43 (2012): 2199–2210. 7. Makeev, A., Seon, G., Cline, J. and Shonkwiler, B. “In Quest of Methods for Measuring 3D Mechanical Properties of Composites”. Composites Science and Technology 100 (2014): 105-112. 8. Seon, G., Makeev, A., Cline, J. and Shonkwiler, B. “Assessing 3D Shear Stress-Strain Properties of Composites Using Digital Image Correlation and Finite Element Analysis Based Optimization”. Composites Science and Technology 117 (2015): 371-378. 9. Makeev, A. “Interlaminar Shear Fatigue Behavior of Glass/Epoxy and Carbon/Epoxy Composites”. Composites Science and Technology 80 (2013): 93–100. 10. Documentation page for SciPy library: https://docs.scipy.org/doc/scipy/reference/generated/ scipy.signal.correlate2d.html. Accessed on Jan 8, 2023.
Conference: SAMPE 2023
Publication Date: 2023/04/17
Price: $32.00Get This Paper