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Simulation of thermoplastic 3D-printed parts for crash applications

Vinot, Mathieu and Bühler, Lars and Behling, Tobias and Holzapfel, Martin and Toso, Nathalie (2023) Simulation of thermoplastic 3D-printed parts for crash applications. 14th European LS-DYNA Conference, 2023-10-18 - 2023-10-19, Baden-Baden, Germany.

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The rapid development of additive manufacturing techniques in aeronautic and automotive industry opens new possibilities in the design of metallic or composite parts compared to traditional subtractive processes. In particular, 3D printing allows the design of complex parts with a high lightweight potential through optimal use of material along the load paths. In the composite field, various printing techniques emerged in the last decade such as Selective Laser Sintering (SLS) or Fused Deposition Modelling (FDM). On the downside, 3D printing is confronted to the large influence of process parameters on the geometrical and optical quality as well as on the mechanical properties of the manufactured structures. Moreover, simulation techniques with finite-element methods are still at their very beginning and improvements should be achieved to predict structural performances in crash applications. This paper focuses on the characterization and simulation of structures manufactured with the Screw Extrusion Additive Manufacturing (SEAM) technique presented in Figure 1. The material investigated is a combination of PA6 resin reinforced with 30% carbon fibres in weight. The mechanical behaviour under various loadings (tension, compression, shear) is first investigated in different material directions relative to the building direction with help of coupon specimens extracted from printed structures. The obtained properties are then fed in an anisotropic material card *MAT157_ANISOTROPIC_ELASTIC_PLASTIC and the respective performances studied by reproducing numerically the experimental tests. This contribution illustrates potential numerical solutions to recreate the mechanical behaviour between the printed layers and gives an insight into their advantages and drawbacks. Finally, an application of the suggested approach to generic honeycomb structures is presented and the gaps in simulation technique are analysed.

Item URL in elib:https://elib.dlr.de/198336/
Document Type:Conference or Workshop Item (Speech)
Title:Simulation of thermoplastic 3D-printed parts for crash applications
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Vinot, MathieuUNSPECIFIEDhttps://orcid.org/0000-0003-3394-5142UNSPECIFIED
Bühler, LarsUNSPECIFIEDhttps://orcid.org/0009-0009-0375-3765UNSPECIFIED
Toso, NathalieUNSPECIFIEDhttps://orcid.org/0000-0003-2803-1450UNSPECIFIED
Date:October 2023
Refereed publication:No
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:additive manufacturing, thermoplastic material, numerical simulation, cohesive zone model
Event Title:14th European LS-DYNA Conference
Event Location:Baden-Baden, Germany
Event Type:international Conference
Event Start Date:18 October 2023
Event End Date:19 October 2023
Organizer:ANSYS / DYNAmore
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Road Transport
DLR - Research area:Transport
DLR - Program:V ST Straßenverkehr
DLR - Research theme (Project):V - FFAE - Fahrzeugkonzepte, Fahrzeugstruktur, Antriebsstrang und Energiemanagement
Location: Stuttgart
Institutes and Institutions:Institute of Structures and Design > Structural Integrity
Institute of Vehicle Concepts > Vehicle Architectures and Lightweight Design Concepts
Deposited By: Vinot, Mathieu
Deposited On:29 Nov 2023 14:52
Last Modified:24 Apr 2024 20:58

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