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Process analysis of temperature and eigenstrains in stiffening ribs printed on a multi curved structure with a robot-based extrusion process

Winkelmann, Felix and Hein, Robert and Baid, Harsh and Cantarutti, Andrea (2023) Process analysis of temperature and eigenstrains in stiffening ribs printed on a multi curved structure with a robot-based extrusion process. Sim-Am 2023, 25. - 28. Juli 2023, München, Deutschland.

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Abstract

In this study, we investigate simulations for a pellet-based extrusion process with high-performance materials for 3D printing. The utilization of a robotic arm equipped with an extruder mounted on it has opened up new avenues for 3D printing, such as printing on curved surfaces or large overhangs without requiring additional support structures. In this research, our focus is on a doubly curved Carbon Fiber Reinforced Polymer (CFRP) structure, which has been strengthened by adding short fiber-reinforced ribs. These ribs are printed onto the curved surface of the structure to enhance its stiffness. However, during the high-temperature printing process with highperformance materials, significant temperature gradients occur, leading to eigenstrains and deformation of the ribs. To predict the impact of these effects on the stiffness of the structure, a process simulation is conducted by using the GENOA 3DP software suite from Alpha STAR Corp. The proposed AM process simulation takes into account AM parameters such as the toolpath (Gcode), deposition rate and extrusion temperature. The thermophysical process is modelled by an element-by-element activation based on the toolpath so that local temperature gradients are captured. This allows the consideration of manufacturing related effects for the prediction of process-dependent material and component properties. The primary objectives of this study are to simulate the intricate extrusion process and to estimate the eigenstrains and deformations that occur during the process as well as to gain an in- depth understanding of the process for further optimisation.

Item URL in elib:https://elib.dlr.de/197193/
Document Type:Conference or Workshop Item (Speech)
Title:Process analysis of temperature and eigenstrains in stiffening ribs printed on a multi curved structure with a robot-based extrusion process
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Winkelmann, FelixUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Hein, RobertUNSPECIFIEDhttps://orcid.org/0000-0002-6258-3673UNSPECIFIED
Baid, HarshAlphastarUNSPECIFIEDUNSPECIFIED
Cantarutti, AndreaAlphastarUNSPECIFIEDUNSPECIFIED
Date:28 July 2023
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:3D Druck, Simulation, Prozesssimulation, Extrusionsprozess
Event Title:Sim-Am 2023
Event Location:München, Deutschland
Event Type:international Conference
Event Dates:25. - 28. Juli 2023
Organizer:Eccomas
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Clean Propulsion
DLR - Research area:Aeronautics
DLR - Program:L CP - Clean Propulsion
DLR - Research theme (Project):L - Advanced Materials and New Manufacturing Technologies, L - Digital Technologies
Location: Braunschweig
Institutes and Institutions:Institut für Systemleichtbau
Institut für Systemleichtbau > Structural Mechanics
Deposited By: Winkelmann, Felix
Deposited On:12 Sep 2023 09:08
Last Modified:12 Sep 2023 09:08

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