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Prediction and optimization of the yield stress of material extrusion specimens made of ABS, using numerical simulation and experimental tests

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Abstract

Material extrusion (ME) is an additive manufacturing technology employed for a wide variety of parts and several applications. Along with its benefits, there are drawbacks regarding ME, such as the anisotropy of specimens that provides different values for mechanical properties and residual stresses. There is a need for optimizing the printing parameters since they are linked to the mechanical behavior of printed parts. One way to reach that goal is by carrying out physical experiments that grant accurate results but at a high cost. Another strategy is to simulate the printing process using specialized software. Therefore, it is vital to determine if a simulation approach is robust enough to predict component’s performance. The present study shows the optimization of process parameters to improve the yield strength of printed specimens made of acrylonitrile–butadiene–styrene (ABS). Experimental runs and a numerical simulation based on thermo-mechanical analyses executed in Digimat software are introduced. Taguchi method and analyses of variance (ANOVA) allowed estimating the effects of process parameters and their optimal values to enhance coupon’s yield strength for both approaches. Optimum levels for experimental and simulated results diverge for layer thickness and infill density. The difference between yield stress dictated by physical and simulated values is below 9% for 75% of the experimental runs. Digimat’s simulations gave a good insight into the material extrusion of plastic materials, but when used for the optimization of printing parameters, they provided lower yield stress values than the ones obtained by experimental methods.

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Data availability

The datasets generated during and/or analyzed during the current study are not publicly available as data also form part of an ongoing study but are available from the corresponding author on reasonable request.

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Acknowledgements

The author would like to thank Tecnologico de Monterrey Campus Toluca for providing a 3D printer and material for conducting the experimental trials. Thanks to MSC Software corporation for contributing with a trial license of Digimat and Marc Mentat software.

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Authors and Affiliations

  1. Tecnologico de Monterrey, School of Engineering and Science, Eduardo Monroy Cárdenas 2000, 50110, Toluca, Estado de México, Mexico

    Carmita Camposeco-Negrete

  2. Hexagon Manufacturing Intelligence, MSC Software Corporation, 4675 MacArthur Court, Newport Beach, CA, 92660, USA

    Pierre-Yves Lavertu

  3. Hexagon Manufacturing Intelligence, MSC Software Corporation, 16901 Judy Scholl Way, Round Rock, TX, 78681, USA

    Juan Lopez-de-Alda

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  1. Carmita Camposeco-Negrete
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Correspondence to Carmita Camposeco-Negrete.

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Camposeco-Negrete, C., Lavertu, PY. & Lopez-de-Alda, J. Prediction and optimization of the yield stress of material extrusion specimens made of ABS, using numerical simulation and experimental tests. Int J Adv Manuf Technol 118, 3657–3671 (2022). https://doi.org/10.1007/s00170-021-08180-2

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