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Kinked crack paths in polycarbonate samples printed by fused deposition modelling using criss-cross patterns

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Abstract

Additive manufacturing is unquestionably gaining importance in industry. Due to the layer by layer deposit process, it usually leads to an anisotropic material. A question of importance is whether Linear Elastic Fracture Mechanics can be used to assess their resistance to fracture. In this paper, we investigate this point on polycarbonate printed by Fused Deposition Modelling focusing on a criss-crossed deposit pattern. Thanks to tensile and fracture experiments instrumented by Digital Image Correlation, the material is evidenced to be linear elastic until fracture, nearly isotropic in the 2D printing plane but with a strong fracture anisotropy, leading to systematic crack kinking along the weakest plane. The Stress Intensity Factors evolution is measured across the kink and shown to be in agreement with Amestoy-Leblond’s formula. The fracture toughness is observed to be larger than the bulk value, in agreement with irreversible damage and plasticity that are clearly observable at the scale of the threads.

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Notes

  1. In other words, the crack tip must be far enough of the sample boundary.

  2. For dimensional reasons and linearity of the problem with the loading, the value of \(\mathcal{L}\) depends only on the sample geometry and can be estimated quite straightforwardly by Finite Elements. The value we obtained in this way, has been checked to be in agreement with the literature (Leevers and Radon 1982).

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Acknowledgements

The authors wish to thank Julien Réthoré and Raphaël Langlois for their advice on DIC. Our experimental support team, Nicolas Thurieau and Lahcène Cherfa, and the interns, Safwan Alblihed and Anis Ben Amor, are acknowledged for their help with the set up of the experiments. The support of Direction Génerale de l’Armement (DGA) and Agence de l’Innovation de la Défense (AID) is gratefully acknowledged.

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  1. IMSIA, CNRS, EDF, CEA, ENSTA Paris, Institut Polytechnique de Paris, 828 bd des Maréchaux, 91762, Palaiseau cedex, France

    Thomas Corre & Véronique Lazarus

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  1. Thomas Corre
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  2. Véronique Lazarus
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Correspondence to Thomas Corre.

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Appendix: Numerical values of the function \(F_{pq}(\varphi )\) for an isotropic material

Appendix: Numerical values of the function \(F_{pq}(\varphi )\) for an isotropic material

The paper of Amestoy and Leblond (1992) provides two methods to obtain the values of \(F_{pq}(\varphi )\): the first is a semi-analytical method in which their values can be obtained by solving some integral equations coupled with Anderson’s formula (Eqs. (34)\(_{1}\), (35)\(_{1}\), (36), (39) in there); the second is to use their expression under the form of a 21 terms-serie of \(m=\varphi /\pi \) (Eq. (66) in there).

The values we used here are those obtained by the first method. They can be downloaded as supplemental material. But the series provided in Amestoy and Leblond (1992) should have been used as well without any change in our final conclusions, as both methods yield (without surprise) quiet exactly the same values (see Fig. 11).

Fig. 11
figure 11

Universal Functions \(F_{pq}(\varphi )\) obtained by two different methods from Amestoy and Leblond (1992)

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Corre, T., Lazarus, V. Kinked crack paths in polycarbonate samples printed by fused deposition modelling using criss-cross patterns. Int J Fract 230, 19–31 (2021). https://doi.org/10.1007/s10704-021-00518-x

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