Fused Deposition Modeling (FDM) technique is a subcategory of additive manufacturing processes that works by extruding a fine polymeric filament on the heated bed. The current research paper surveys the influence of nozzle diameter as a manufacturing parameter on the mechanical properties and mode I fracture behavior of the FDM-PLA samples. Four different nozzle diameters of 0.4, 0.6, 0.8, and 1 mm with two raster configurations of 0/90° and 45/-45° were considered for printing the dog-bone and Semi-Circular Bending (SCB) samples. Also, to evaluate the fracture resistance of FDM-PLA pre-cracked samples, the critical value of J-integral (Jc) was used and calculated through a finite element analysis. The obtained results indicated that the raster angle of 45/-45° resulted in higher mechanical properties compared to 0/90° one, also, the 1 mm nozzle diameter presented a better performance from a mechanical property point of view. The SCB sample printed through the 1 mm nozzle diameter and 45/-45° raster orientation had the highest value of Jc (10400 J/m2). Besides, the crack extension paths were monitored and discussed comprehensively.
In engineering applications, considering the growing utilization of Polylactic acid (PLA) material manufactured through material extrusion (MEX) additive manufacturing techniques, it becomes imperative to predict its fracture behavior to assess damage thoroughly under various loading scenarios. As an initial step, this study focuses on determining the Mode-I fracture toughness of the PLA material manufactured by MEX in three different print orientations through a three-point (3P) bending fracture test. The raster angle utilized to fabricate the single-edge notch bending (SENB) specimens was chosen as ±45°. Three different print orientations were used to investigate the effects of printing direction (i.e., horizontal, lateral, and vertical) on the fracture properties. The fracture properties were extracted per the standard ASTM D5045-14 on the specimens fabricated in three different print orientations. The values of Mode-I fracture toughness of PLA were respectively obtained as 4.22, 4.18, and 3.56 MPa/m with horizontal, lateral, and vertical print orientation. Then, corresponding fracture energy values were calculated for numerical investigations. A commercial finite element package was utilized to employ the extracted values into the extended finite element method (XFEM) and investigate the crack propagation in the specimens. It was found that the numerical analyses well simulated the crack propagation and peak load (damage initiation point) experienced in the SENB specimens tested under 3P bending loading.
This work explores the effects of notching method and element layout on the fracture loading properties of thermoplastic materials processed using fused filament fabrication (FFF). Three common thermoplastic materials were used (acrylonitrile butadiene styrene, polylatide, and polycarbonate). Four different notching methods were used, with printed and machined notches and with and without pre-cracking on ASTM D5045 compact tension specimens (n = 36). It was concluded that the notching method has a statistically significant impact on the sample preparation and that pre-cracking is necessary in all cases. Using this information to prepare specimens, a designed experiment using four different element layout strategies and two different nozzle sizes was completed with a total of 72 tests. The layout pattern was shown to have a very strong effect on the maximum fracture load, with the nozzle size showing a smaller but still statistically significant impact. With the exception of one layout using polycarbonate with likely design-driven printing defects, the results were very consistent through several replications. The results of this study are useful for making design decisions with FFF-processed materials, for better understanding the impact of the process design, and for working toward standardized printing and testing methods for additive manufacturing.