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Experimental and Numerical Investigation on Mechanical Properties of Continuous Fiber Reinforced Parts Fabricated with FDM Additive Manufacturing Method

Arjmandi, Mohammad | 2023

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 55940 (45)
  4. University: Sharif University of Technology
  5. Department: Aerospace Engineering
  6. Advisor(s): Yousefi, Reza; Kouchakzadeh, Mohammad Ali
  7. Abstract:
  8. With advancement of science of aircraft design and limitations of traditional manufacturing methods, using new ones in order to improve efficiency is needed. Among those methods to improve structure efficiency are weight reduction or increase in strength. Increasing strength-to-weight ratio and reduction of weight could be achieved by using composite materials and topology optimization respectively. Manufacturing such parts with efficient design using traditional methods is hard or impossible. Additive manufacturing as a new technology which is being developed every day, can be a big help to aerospace industry. Considering the importance of strength-to-weight ratio in aerospace industry and broadness of FDM printers, adding reinforcer fibers in the direction of applied force to parts made by this method can cause weight reduction, increase in tolerable load and as a result increase in structure efficiency. Composite FDM printers that automaticly use continuous fiber to reinforce parts have been built, but there is only one in Iran (claime of the manufacturer) and in addition to the limitations in part manufacturing (2D layering, limitations of fiber placement, ...), are many times more expensive than the usual FDM printers In this research, initially a method for reinforcing parts built using FDM method with the goal of improving performance has been introduced. This method, uses results from topology optimization, optimized path for placing reinforcers with considering mates and designed by the user. Considering wide use of brackets, an asymmetric one is chosen for investigation. Finite element analysis and laboratory examination have been done to verify the results. The parameter in question for investigating parts after reinforcement, is the force-displacement diagram in constant mass. Force-to-mass ratio has also been used for investigating the effects of fiber mass ratio. Abaqus has been used for all FEM analysis, whether topology optimization or static analysis of parts. PLA, epoxy resin and carbon fibre have been used in the manufacturing of part. For the part in question over 700 percent increase in fracture load was observed depending on the path and mass ratio of reinforcer
  9. Keywords:
  10. Additive Manufacturing ; Topology Optimization ; Carbon Fibers ; Tensile Test ; Three Dimensional Printer ; Fused Deposition Modeling (FDM) ; Mechanical Properties

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