Multiscale numerical modeling of large-format additive manufacturing processes using carbon fiber reinforced polymer for digital twin applications

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING International Journal of Material Forming Pub Date : 2024-01-15 DOI:10.1007/s12289-024-01811-5

Pablo Castelló-Pedrero, César García-Gascón, Juan A. García-Manrique

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Abstract

Large Format Additive Manufacturing (LFAM) has gained prominence in the aerospace and automotive industries, where topology optimization has become crucial. LFAM facilitates the layer-by-layer production of sizeable industrial components in carbon fiber (CF) reinforced polymers, however 3D printing at large scales results in warpage generation. Printed components are deformed as residual stresses generated due to thermal gradients between adjacent layers. This paper tackles the problem at two different scales: the micro and macroscale. Initially, the microstructure characterization of the thermoplastic ABS matrix composite material enriched with 20% short CF is used in the development of numerical models to understand the mechanical behavior of the studied material. Numerical modeling is performed simultaneously by means of Mean-Field (MF) homogenization methods and Finite Element Analysis (FEA). Outcomes validated with corrected experimental mechanical testing results show a discrepancy in the elastic modulus of 7.8% with respect to FE multi-layer analysis. Micro-level results are coupled with the a macroscopic approach to reproduce the LFAM process, demonstrating the feasibility of the tool in the development of a Digital Twin (DT).

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针对数字孪生应用的碳纤维增强聚合物大型增材制造工艺的多尺度数值建模

大幅面增材制造（LFAM）在航空航天和汽车行业中的地位日益突出，拓扑优化在这些行业中变得至关重要。大尺寸增材制造有利于用碳纤维（CF）增强聚合物逐层生产大型工业部件，但大规模三维打印会产生翘曲。相邻层之间的热梯度会产生残余应力，导致打印部件变形。本文从微观和宏观两个不同尺度来解决这一问题。首先，在开发数值模型时使用了富含 20% 短 CF 的热塑性 ABS 基复合材料的微观结构特征，以了解所研究材料的机械行为。数值建模通过平均场（MF）均质化方法和有限元分析（FEA）方法同时进行。与修正后的实验机械测试结果验证的结果显示，弹性模量与有限元多层分析的差异为 7.8%。微观结果与重现 LFAM 过程的宏观方法相结合，证明了该工具在数字孪生（DT）开发中的可行性。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.