Additive manufacturing of continuous fibre reinforced thermoplastic composites using fused deposition modelling: Effect of process parameters on mechanical properties
Continuous Fibre Reinforced Thermoplastic Composites (CFRTPCs) are becoming alternative materials to replace the conventional thermosetting polymers and metals due to excellent mechanical performance, recycling and potential used in lightweight structures. Fused deposition modelling (FDM) is a promi...
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| Published in: | Composites science and technology Vol. 181; p. 107688 |
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| Main Authors: | , , , , , |
| Format: | Journal Article |
| Language: | English |
| Published: |
Barking
Elsevier Ltd
08.09.2019
Elsevier BV |
| Subjects: | |
| ISSN: | 0266-3538, 1879-1050 |
| Online Access: | Get full text |
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| Abstract | Continuous Fibre Reinforced Thermoplastic Composites (CFRTPCs) are becoming alternative materials to replace the conventional thermosetting polymers and metals due to excellent mechanical performance, recycling and potential used in lightweight structures. Fused deposition modelling (FDM) is a promising additive manufacturing technology and an alternative of conventional processes for the fabrication of CFRTPCs due to its ability to build functional parts having complex geometries. The mechanical properties of a built part depend on several process parameters. The aim of this study is to characterize the effect of build orientation, layer thickness and fibre volume content on the mechanical performance of 3D printed continuous fibre reinforced composites components manufactured by a desktop 3D printer. Tensile and three-point bending tests are carried out to determine the mechanical response of the printed specimens. SEM images of fractured surfaces are evaluated to determine the effects of process parameters on failure modes.
It is observed that the effect of layer thickness of nylon samples on the mechanical performance is marginally significant. In addition, continuous fibre reinforced samples show higher strength and stiffness values than unreinforced ones. The results show that carbon fibre reinforced composites exhibit the best mechanical performance with higher stiffness and flat samples exhibit higher values of strength and stiffness than on-edge samples. Additionally, the results show that strength and stiffness increase as fibre volume content increases in most cases but, conversely, the level of increment in mechanical performance is moderate with continued rise in fibre content, particularly in the case of Kevlar® and glass fibres, due to weak bonding between the fibre/nylon layers as well as the presence of increased levels of defects. Finally, the practicality of the results is assessed by testing an evaluation structure. |
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| AbstractList | Continuous Fibre Reinforced Thermoplastic Composites (CFRTPCs) are becoming alternative materials to replace the conventional thermosetting polymers and metals due to excellent mechanical performance, recycling and potential used in lightweight structures. Fused deposition modelling (FDM) is a promising additive manufacturing technology and an alternative of conventional processes for the fabrication of CFRTPCs due to its ability to build functional parts having complex geometries. The mechanical properties of a built part depend on several process parameters. The aim of this study is to characterize the effect of build orientation, layer thickness and fibre volume content on the mechanical performance of 3D printed continuous fibre reinforced composites components manufactured by a desktop 3D printer. Tensile and three-point bending tests are carried out to determine the mechanical response of the printed specimens. SEM images of fractured surfaces are evaluated to determine the effects of process parameters on failure modes. It is observed that the effect of layer thickness of nylon samples on the mechanical performance is marginally significant. In addition, continuous fibre reinforced samples show higher strength and stiffness values than unreinforced ones. The results show that carbon fibre reinforced composites exhibit the best mechanical performance with higher stiffness and flat samples exhibit higher values of strength and stiffness than on-edge samples. Additionally, the results show that strength and stiffness increase as fibre volume content increases in most cases but, conversely, the level of increment in mechanical performance is moderate with continued rise in fibre content, particularly in the case of Kevlar® and glass fibres, due to weak bonding between the fibre/nylon layers as well as the presence of increased levels of defects. Finally, the practicality of the results is assessed by testing an evaluation structure. Continuous Fibre Reinforced Thermoplastic Composites (CFRTPCs) are becoming alternative materials to replace the conventional thermosetting polymers and metals due to excellent mechanical performance, recycling and potential used in lightweight structures. Fused deposition modelling (FDM) is a promising additive manufacturing technology and an alternative of conventional processes for the fabrication of CFRTPCs due to its ability to build functional parts having complex geometries. The mechanical properties of a built part depend on several process parameters. The aim of this study is to characterize the effect of build orientation, layer thickness and fibre volume content on the mechanical performance of 3D printed continuous fibre reinforced composites components manufactured by a desktop 3D printer. Tensile and three-point bending tests are carried out to determine the mechanical response of the printed specimens. SEM images of fractured surfaces are evaluated to determine the effects of process parameters on failure modes. It is observed that the effect of layer thickness of nylon samples on the mechanical performance is marginally significant. In addition, continuous fibre reinforced samples show higher strength and stiffness values than unreinforced ones. The results show that carbon fibre reinforced composites exhibit the best mechanical performance with higher stiffness and flat samples exhibit higher values of strength and stiffness than on-edge samples. Additionally, the results show that strength and stiffness increase as fibre volume content increases in most cases but, conversely, the level of increment in mechanical performance is moderate with continued rise in fibre content, particularly in the case of Kevlar® and glass fibres, due to weak bonding between the fibre/nylon layers as well as the presence of increased levels of defects. Finally, the practicality of the results is assessed by testing an evaluation structure. |
| ArticleNumber | 107688 |
| Author | Chacón, J.M. Caminero, M.A. García-Plaza, E. García-Moreno, I. Reverte, J.M. Núñez, P.J. |
| Author_xml | – sequence: 1 givenname: J.M. surname: Chacón fullname: Chacón, J.M. organization: Escuela Técnica Superior de Ingenieros Industriales, IMACI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain – sequence: 2 givenname: M.A. surname: Caminero fullname: Caminero, M.A. email: miguelangel.caminero@uclm.es organization: Escuela Técnica Superior de Ingenieros Industriales, INEI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain – sequence: 3 givenname: P.J. surname: Núñez fullname: Núñez, P.J. organization: Escuela Técnica Superior de Ingenieros Industriales, INEI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain – sequence: 4 givenname: E. surname: García-Plaza fullname: García-Plaza, E. organization: Escuela Técnica Superior de Ingenieros Industriales, INEI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain – sequence: 5 givenname: I. surname: García-Moreno fullname: García-Moreno, I. organization: Escuela Técnica Superior de Ingenieros Industriales, INEI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain – sequence: 6 givenname: J.M. surname: Reverte fullname: Reverte, J.M. organization: Escuela Técnica Superior de Ingenieros Industriales, IMACI, Universidad de Castilla-La Mancha. Avda, Camilo José Cela s/n, 13005, Ciudad Real, Spain |
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| SubjectTerms | 3D printing Additive manufacturing Aramid fibers Bonding strength Carbon fiber reinforced plastics Carbon fibers Composite materials Continuous fiber composites Continuous fibre reinforced thermoplastic composites Failure analysis Failure modes Fiber composites Fiber reinforced polymers Fiber volume fraction Fused deposition modeling Fused deposition modelling Glass fiber reinforced plastics Kevlar (trademark) Mathematical models Mechanical analysis Mechanical characterization Mechanical properties Modelling Orientation effects Polymer matrix composites Process parameters Stiffness Tensile strength Thickness Three dimensional printing |
| Title | Additive manufacturing of continuous fibre reinforced thermoplastic composites using fused deposition modelling: Effect of process parameters on mechanical properties |
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