Simulating Additive Manufacturing Material Extrusion Processes with Short Fiber-Reinforced Polymer Materials

Abstract

In Additive Manufacturing with Continuous Fiber-Reinforced Polymer (AM-CFRP) Materials, parts are created by successively adding material in a defined space. While additive extrusion could be used with a wide range of materials, those involving CFRP represent one of the greatest challenges for modelling approaches. Compared to many isotropic metal 3d printing processes, AM-CFRP is characterized by anisotropic material properties. The path planning (CAM) and machine language used (G-code) has a direct influence on the local material orientations and hence will determine the structural and thermal response of the final component. In this presentation, an advanced simulation model that accounts for material anisotropy based on the build strategy used will be discussed. The simulation will consider a more accurate approach to generating a geometric representation of the manufactured part, based on machine build strategy. In addition, the results obtained with a demonstration part created in collaboration with the DLR Innovation Lab EmpowerAX platform will be analysed. A complete macroscale simulation workflow using different capabilities available in Ansys will be presented.