Numerical Evaluation of the Effective Thermo-Mechanical Properties of a Large-Scale Additively Manufactured Short Fiber-Reinforced Polymer Composite

This study presents a finite element analysis (FEA)-based numerical homogenization method for evaluating the effective thermo-mechanical properties of a large-area additively manufactured particulate-filled composite using realistic periodic representative volume elements (RVEs) generated from reconstructed X-ray µ-CT image scans of a 3D-printed bead. The numerical results of the predicted effective properties, including the elastic stiffness, coefficient of thermal expansion (CTE) and thermal conductivity, were benchmarked with the Mori–Tanaka–Benveniste analytical estimates, which were found to be comparable. Initial sensitivity analysis using a single region of interest (ROI) extracted from the bead’s volume was performed to determine a suitable RVE size. The impact of inherent micro-porosities on the resulting composite material’s behavior was also quantified in the current investigation and was shown to reduce the composite’s effective properties. Using a suitable RVE size, the effect of anisotropy due to spatial variation in the microstructure across the bead specimen on the computed composite’s effective properties was also assessed. The results show that the regions closer to the exposed surface of the print bead with highly aligned and densely packed fiber particulates have superior properties as compared to inner regions with a more randomly oriented and less densely packed fibrous microstructure.