Thermo-mechanical analysis of additive manufacturing for material properties estimation of layered polymer composite

Abstract This paper proposes a numerical approach for predicting residual stresses induced during the additive manufacturing (AM) of polymer composites and their effect on the deformation behavior of the composites. A finite element (FE) model was developed on Abaqus/Standard for 3D printing of layered polymer composite using three polymers: HDPE, PVC, and ABS. The material properties of pure polymers and their blends were measured through tensile testing of injection-molded specimens. These properties were then used as input data in the FE model for the regions of pure polymers and their interfaces. An uncoupled thermo-mechanical analysis was performed, where a heat transfer analysis was realized first using elements birth (activation/deactivation) technique and a moving cylindrical volumetric heat source as a Fortran subroutine (DFLUX). With temperature input from thermal simulation, a mechanical analysis was carried out to deform the polymer composites along and across the print direction, i.e. under isostrain and isostress conditions, respectively. It was observed that the theoretical models existing in the literature underestimate the material properties as they do not consider the residual stresses developed during fabrication. The FE simulations predicted that the estimated material properties were 10 to 50% different from those calculated by the theoretical models, depending upon the residual stress level and the print direction.