Abstract
The widespread use of additive manufacturing (AM) has been extensively progressed in the past decade due to the convenience provided by AM in rapid and reliable part production. Fused deposition modeling (FDM) has witnessed even faster growth of application as its equipment is environmentally friendly and easily adaptable. This increased use of FDM to manufacture prototypes and finished parts is accompanied by concerns that 3D printed parts do not perform the same as relatively homogeneous parts produced by molding or machining. As the interface between two faces of bonded material may be modeled by stress elements, in theory, by modeling 3D printed layers subjected to tension at varying angles as transformed stress elements, the stress required to break the layer bonds can be determined. To evaluate such a relationship, in this study, the stresses calculated from stress transformation were compared with the behavior of 3D printed specimens subjected to tensile loads. The maximum principal stress was found to be constant relative to the layer angle, regardless of whether the specimen experienced failure at the layer interface or within the layer material, although the specimens with layers 75° relative to the load were notable exceptions to this finding. This failure at much lower stresses for the samples used in the 75° tests may be attributed to a possible environmental factor, such as temperature or humidity change, degrading the samples’ structural integrity.
Similar content being viewed by others
Availability of data and material
The raw/processed data required to reproduce these findings will be made available on request.
Code availability
Not applicable.
References
Sehhat MH, Mahdianikhotbesara A, Hadad M (2022) Formability Investigation for perforated steel sheets. SAE Int J Mater Manuf 15:05–15–02–0012. https://doi.org/10.4271/05-15-02-0012
Mahdianikhotbesara A, Sehhat MH, Hadad M (2021) Experimental study on micro-friction stir welding of dissimilar butt joints between Al 1050 and pure copper. Metallogr Microstruct Anal 2021:1–16. https://doi.org/10.1007/S13632-021-00771-5
Nezhadfar PD, Zarei-Hanzaki A, Sohn SS, Abedi HR (2016) Characterization of twin-like structure in a ferrite-based lightweight steel. Met Mater Int 225(22):810–816. https://doi.org/10.1007/S12540-016-6113-7
Sehhat MH, Mahdianikhotbesara A, Yadegari F (2021) Experimental validation of conductive heat transfer theory: thermal resistivity and system effects. Comput Res Prog Appl Sci Eng 7:1–6. https://doi.org/10.52547/CRPASE.7.4.241
Mahdianikhotbesara A, Sehhat MH, Hadad M (2022) A numerical and experimental study into thermal behavior of micro friction stir welded joints of Al 1050 and Copper Sheets. AMR 1170:49–60. https://doi.org/10.4028/p-01ag12
Sehhat MH, Behdani B, Hung CH, Mahdianikhotbesara A (2021) Development of an empirical model on melt pool variation in laser foil printing additive manufacturing process using statistical analysis. Metallogr Microstruct Anal 10:684–691. https://doi.org/10.1007/s13632-021-00795-x
Hung CH, Chen WT, Sehhat MH, Leu MC (2020) The effect of laser welding modes on mechanical properties and microstructure of 304L stainless steel parts fabricated by laser-foil-printing additive manufacturing. Int J Adv Manuf Technol 1–11. https://doi.org/10.1007/s00170-020-06402-7
Hung C-H, Turk T, Sehhat MH, Leu MC (2022) Development and experimental study of an automated laser-foil-printing additive manufacturing system. Rapid Prototyp J ahead-of-print. https://doi.org/10.1108/RPJ-10-2021-0269
Turk T, Hung C-H, Hossein Sehhat M, Leu MC (2021) Methods of automating the laser-foil-printing additive manufacturing process. https://doi.org/10.26153/TSW/17633
The transformative potential of additive manufacturing | Request PDF (n.d.) https://www.researchgate.net/publication/267517809_The_Transformative_Potential_of_Additive_Manufacturing (Accessed 5 Feb 2022)
Mechanical properties of parts formed by laser additive manufacturing | Request PDF (n.d.) https://www.researchgate.net/publication/285853918_Mechanical_Properties_of_Parts_Formed_by_Laser_Additive_Manufacturing (Accessed 5 Feb 2022)
Kundakcioglu E, Lazoglu I, Rawal S (2015) Transient thermal modeling of laser-based additive manufacturing for 3D freeform structures. Int J Adv Manuf Technol 851(85):493–501. https://doi.org/10.1007/S00170-015-7932-2
Kundakcıoğlu E, Lazoglu I, Poyraz Ö, Yasa E, Cizicioğlu N (2018) Thermal and molten pool model in selective laser melting process of Inconel 625. Int J Adv Manuf Technol 959(95):3977–3984. https://doi.org/10.1007/S00170-017-1489-1
Khan SA, Lazoglu I (2019) Development of additively manufacturable and electrically conductive graphite–polymer composites. Prog Addit Manuf 52(5):153–162. https://doi.org/10.1007/S40964-019-00102-9
Isa MA, Lazoglu I (2019). Five-axis additive manufacturing of freeform models through buildup of transition layers. https://doi.org/10.1016/j.jmsy.2018.12.002
Yigit IE, Lazoglu I (2019) Helical slicing method for material extrusion-based robotic additive manufacturing 5-axis Additive Manufacturing System View project Development of An Open-Architecture Rapid Prototyping System View project Helical slicing method for material extrusion-based robotic additive manufacturing 4:225–232. https://doi.org/10.1007/s40964-019-00090-w
Yigit IE, Lazoglu I (2020) Spherical slicing method and its application on robotic additive manufacturing. Prog Addit Manuf 54(5):387–394. https://doi.org/10.1007/S40964-020-00135-5
Yigit IE, Isa M, Lazoglu I (2018) Additive manufacturing with modular support structures. https://doi.org/10.26153/TSW/17208
Isa MA, Yiğit IE, Lazoglu I (2018) Analysis of build direction in deposition-based additive manufacturing of overhang structures. https://doi.org/10.26153/TSW/17156
Yigit IE, Lazoglu I (2019) Dynamic build bed for additive manufacturing. https://doi.org/10.26153/TSW/17381
Yigit IE, Khan SA, Lazoglu I, Yigit IE, Khan SA (n.d.) Robotic additive manufacturing of tooling for composite structures development of an open-architecture rapid prototyping system view project additive manufacturing with funtional materials view project. Robot Addit Manuf Tool Compos Struct. https://www.researchgate.net/publication/345921432 (Accessed 22 Jan 2022)
Behdani B, Senter M, Mason L, Leu M, Park J (2020) Numerical study on the temperature-dependent viscosity effect on the strand shape in extrusion-based additive manufacturing. J Manuf Mater Process 4:46. https://doi.org/10.3390/jmmp4020046
Sehhat MH, Mahdianikhotbesara A, Yadegari F (2022) Impact of temperature and material variation on mechanical properties of parts fabricated with fused deposition modeling (FDM) additive manufacturing. Int J Adv Manuf Technol 120:4791–4801. https://doi.org/10.1007/s00170-022-09043-0
Sehhat MH (2021) Ali Mahdianikhotbesara. Powder spreading in laser-powder bed fusion process. Granul Matter 23:89. https://doi.org/10.1007/s10035-021-01162-x
Sehhat MH, Chandler J, Yates Z (2022) A review on ICP powder plasma spheroidization process parameters. International Journal of Refractory Metals and Hard Materials 103. https://doi.org/10.1016/j.ijrmhm.2021.105764
Sehhat MH, Sutton AT, Hung C-H, Newkirk JW, Leu MC (2021) Investigation of mechanical properties of parts fabricated with gas- and water-atomized 304L stainless steel powder in the laser powder bed fusion process. JOM 2021:1–8. https://doi.org/10.1007/S11837-021-05029-7
Liu T, Lough CS, Sehhat H, Huang J, Kinzel EC, Leu MC (2021) In-situ thermographic inspection for laser powder bed fusion. Int Solid Free Fabr Symp. University of Texas at Austin. https://doi.org/10.26153/tsw/17556
Sehhat MH, Sutton AT, Hung CH et al (2022) Plasma spheroidization of gas-atomized 304L stainless steel powder for laser powder bed fusion process. Mater Sci Add Manuf 1(1):1. https://doi.org/10.18063/msam.v1i1.1
Sehhat MH, Sutton AT, Leu MC (2022) Enhancement of gas-atomized 304L stainless steel powder by plasma spheroidization for use in the laser powder bed fusion process. United States: N. p. https://doi.org/10.2172/1876883
Sehhat MH, Sutton AT, Yates Z, Leu MC (2022) Effects of recoating velocity and layer thickness on the powder-bed surface roughness in the laser powder bed fusion (LPBF) process, Int Solid Free Fabr Symp. University of Texas at Austin
Sehhat MH, Cullom T, Newkirk JW (2022) Characterization of Virgin, recycled, and oxygen-reduced copper powders processed by the plasma spheroidization, research square. https://doi.org/10.21203/rs.3.rs-1840008/v1
Liu T, Lough CS, Sehhat MH, Ren YM, Christofides PD, Kinzel EC, Leu MC (2022) In-situ infrared thermographic inspection for local powder layer thickness measurement in laser powder bed fusion. Additive Manufacturing 55:2214–8604. https://doi.org/10.1016/j.addma.2022.102873
Liou A-C, Chen R-H (2006) Injection molding of polymer micro-and sub-micron structures with high-aspect ratios. Int J Adv Manuf Technol 28:1097–1103. https://doi.org/10.1007/s00170-004-2455-2
Su YC, Shah J, Lin L (2003) Implementation and analysis of polymeric microstructure replication by micro injection molding. J Micromech Microeng 14:415. https://doi.org/10.1088/0960-1317/14/3/015
Esposito Corcione C, Gervaso F, Scalera F, Montagna F, Sannino A, Maffezzoli A (2017) The feasibility of printing polylactic acid–nanohydroxyapatite composites using a low-cost fused deposition modeling 3D printer. J Appl Polym Sci 134:44656. https://doi.org/10.1002/APP.44656
Syrlybayev D, Zharylkassyn B, Seisekulova A, Akhmetov M, Perveen A, Talamona D (2021) Optimisation of strength properties of FDM printed parts-a critical review. Polymers (Basel). https://doi.org/10.3390/POLYM13101587
Messimer SL, Pereira TR, Patterson AE, Lubna M, Drozda FO (2019) Full-density fused deposition modeling dimensional error as a function of raster angle and build orientation: large dataset for eleven materials. J Manuf Mater Process 3:6. https://doi.org/10.3390/JMMP3010006
Casavola C, Cazzato A, Moramarco V, Renna G (2019) Mechanical behaviour of ABS-Fused Filament Fabrication compounds under impact tensile loadings. Materials (Basel). https://doi.org/10.3390/MA12081295
Hambali RH, Smith P, Rennie AEW (2012) Determination of the effect of part orientation to the strength value on additive manufacturing FDM for end-use parts by physical testing and validation via three-dimensional finite element analysis. Int J Mater Eng Innov 3:269–281. https://doi.org/10.1504/IJMATEI.2012.049266
Rafi AH, Ahmed DH (2022) Two-dimensional analogies to the deformation characteristics of a falling droplet and its collision. 0–2. https://doi.org/10.24425/ame.2021.139649
Nezhadfar PD, Thompson S, Saharan A, Phan N, Shamsaei N (2021) Structural integrity of additively manufactured aluminum alloys: effects of build orientation on microstructure, porosity, and fatigue behavior. Addit Manuf 47:102292. https://doi.org/10.1016/J.ADDMA.2021.102292
Nezhadfar PD, Shamsaei N, Phan N (2021) Enhancing ductility and fatigue strength of additively manufactured metallic materials by preheating the build platform. Fatigue Fract Eng Mater Struct 44:257–270. https://doi.org/10.1111/FFE.13372
Jirandehi AP, Chakherlou TN (2019) A fatigue crack initiation and growth life estimation method in single-bolted connections. J Strain Anal Eng Des 54:79–94. https://doi.org/10.1177/0309324719829274
Ghadimi H, Jirandehi AP, Nemati S, Guo S (2021) Small-sized specimen design with the provision for high-frequency bending-fatigue testing. Fatigue Fract Eng Mater Struct. https://doi.org/10.1111/FFE.13589
Chenarani V, Mahdianikhotbesara A, Hadad M, Sehhat MH, Hedayati-Dezfooli M, Araee A, Zaheri A, (2022) Evaluation of the forming limit diagram (FLD) for St-Mg-St multilayer sheet manufactured by transient liquid phase (TLP) bonding. Metallogr Microstruct Anal
Ziemian C, Sharma M, Ziemian S (n.d.) 7 anisotropic mechanical properties of ABS parts fabricated by fused deposition modelling. www.intechopen.com (Accessed 9 Nov 2021)
Yadegari F, Sehhat MH, Mahdianikhotbesara A (2022) A numerical study of automotive body panel draw dies defects using finite element simulation. https://doi.org/10.21203/RS.3.RS-1300589/V1
Yadegari F, Mahdianikhotbesara A, Sehhat MH (2022) Design and Modeling of a High-Acceleration MEMS GSwitch. Computational Research Progress in Applied Science & Engineering, CRPASE: Transactions of Mechanical Engineering 8:1–5
Mechanics of Materials: Stress Transformation » Mechanics of Slender Structures | Boston University (n.d.) https://www.bu.edu/moss/mechanics-of-materials-stress-transformation/ (Accessed 19 Nov 2021)
ASTM D638 - 14 Standard Test Method for Tensile Properties of Plastics (n.d.) https://www.astm.org/Standards/D638 (Accessed 12 Nov 2021)
Lanzotti A, Grasso M, Staiano G, Martorelli M (2015) The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer. Rapid Prototyp J 21:604–617. https://doi.org/10.1108/RPJ-09-2014-0135/FULL/XML
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Ethics approval
The manuscript contains original ideas which have never been published before in other journals.
Consent to participate
This study is not a human transplantation study. No consent needed for this paper.
Consent for publication
The authors declare their consent for publication.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Sehhat, M.H., Mahdianikhotbesara, A. & Yadegari, F. Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM). Int J Adv Manuf Technol 123, 1777–1783 (2022). https://doi.org/10.1007/s00170-022-10321-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-10321-0