Abstract
Distortion and buildup of residual stresses are common design problems in structures manufactured using additive manufacturing techniques, popularly known as 3D printing. These problems lead to poor product quality, which often is improved by trial and error, where the sensitivity of different manufacturing configurations to product quality are experimentally determined. With the introduction of Big Area Additive Manufacturing (BAAM), where significant amount of material is deposited per unit time, trial and error philosophy reduces the economical efficiency of the process. In this work, a numerical simulation methodology based on Finite Element Method (FEM), multi-scale damage mechanics and fracture mechanics is introduced to simulate the BAAM process for determining product quality in terms of distortions, material damage and interface fracture due to manufacturing. In addition, this tool can be used to obtain the sensitivities of the manufacturing configurations with respect to product quality in an economically efficient manner compared to the trial and error philosophy. Computational tools providing a fully coupled thermo-mechanical solution of polymer additive manufacturing with chopped fiber reinforced plastics are presented.
