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Failure of Notched Specimens Made of 3D Printed Materials

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Author
Schmeier, Gina Eileen Chiara
Date
2022-08
Advisor
Kwon, Young Wuk
Sachau, Delf
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Abstract
As an important subcategory of additive manufacturing, fused filament fabricated components have become the focus of scientific attention in recent years. Increasing use in industry as well as in the private sector makes a characterisation of the material behaviour indispensable. Printed materials do not behave exclusively isotopically due to the production process, but exhibit different material strengths depending on the printing direction. The predictability of directional failure loads therefore plays a major role in both component design and application. Catastrophic failures often occur due to unanticipated material failure. This happens especially in already critical areas, which already show material indentations such as holes. In this thesis, experimental tests and material calculations to predict the fracture behaviour are presented. The latter are tested in a finite element analysis with respect to their applicability. Using recently proposed failure criteria, the predictability of material failure as well as the location of occurrence and crack propagation will be evaluated experimentally on brittle orthotropic materials and the criterion used will be verified. Subsequently, this criterion will be applied to fused filament fabrication produced materials with arbitrary printing angle and the failure will be verified experimentally. Finally, conclusions are presented and an outlook on areas that deserve further research is suggested.
 
Als wichtige Unterkategorie der Additiven Fertigung sind mittels fused filament fabrication fabrizierte Bauteile in den letzten Jahren in den Fokus der Wissenschaft gerückt. Zunehmende Verwendung in der Industrie sowie im privaten Bereich machen eine Charakterisierung des Materialverhaltens unabdingbar. Gedruckte Materialien verhalten sich durch den Produktionsprozess nicht ausschliesslich Isotop sondern weisen verschiedene Materialstärken je nach Belastungsrichtung auf. Die Vorhersagbarkeit von richtungsbezogenen Versagenslasten spielt folglich sowohl in der Bauteilkonstuktion sowie in der Anwendung eine grosse Rolle. Häufig kommt es zu katastrophalen Ausfällen aufgrund nicht vorhergesehenem Materialversagen. Dies geschieht insbesondere in bereits kritischen Bereichen, welche bereits Materialeinschnitte wie zum Beispiel Löcher aufweisen. In dieser Thesis werden experimentelle Tests und Materialberechnungen zum Vorhersagen eben jenes Bruchverhaltens vorgestellt. Letztere werden in einer finite Elemente Analyse hinsichtlich ihrer Anwendbarkeit geprüft. Anhand kürzlich vorgeschlagener Versagenskriterien soll die Vorhersagbarkeit von Materialversagen sowie die Stelle des Auftretens und die Rissausbreitung experimentell an spröden, orthotrophen Materialien bewertet und verwendetes Kriterium verifiziert werden. Im Anschluss soll jenes Kriterium auf FFF produzierte Materialien mit belibigem Druckwinkel angewendet werden und das Versagen experimentell verifiziert werden. Als Abschluss werden Schlussfolgerungen dargelegt und ein Ausblick auf Bereiche vorgeschlagen die weitere Forschung verdienen.
 
Description
Prepared for: Space Systems Academics Group, Naval Postgraduate School, Monterey, CA, 93943
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Copyright is reserved by the copyright owner.
URI
https://hdl.handle.net/10945/70962
NPS Report Number
NPS-SP-22-002
Collections
  • 1. Thesis and Dissertation Collection, all items
  • All Technical Reports Collection

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