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International Journal on Interactive Design and Manufacturing (IJIDeM)

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05-03-2023 | Technical Paper

Finite element simulation of additive manufacturing process of carbon allotropes

Authors: Kautilya S. Patel, Susmita D. Solanki, Dhaval B. Shah, S. J. Joshi, K. M. Patel

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) | Issue 9/2024

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Abstract

The article delves into the finite element simulation of additive manufacturing processes for carbon allotropes, such as graphene and carbon nanotubes (CNTs). It examines how different infill patterns—rectilinear and honeycomb—affect the mechanical properties of 3D-printed components. The study uses finite element analysis to investigate the von-Mises stress and total deformation in tensile specimens made from various materials. Experimental validation is conducted to compare the simulation results with real-world tensile testing, revealing that multi-walled CNTs with a honeycomb infill pattern offer superior strength and lower deformation. This research is particularly valuable for optimizing the design and manufacturing processes of high-performance materials in industries requiring high strength-to-weight ratios, such as aerospace and defense.

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Abstract

In a wide range of technical applications, the need for strong yet lightweight materials has significantly increased. Allotropes of carbon are combinations of several elements that exist as crystals. The production of components using 3D printing commonly employs a variety of infill patterns to speed up printing with the use of less material. The proposed study entails employing the chosen 3D printing methods to analyze tensile specimens made from carbon allotropes. On 3D printed parts, the von-Mises stress has been predicted using a finite element simulation. As part of the simulation process, parts are prepared in solid modeling software and then put under tensile loads in ANSYS to determine the desired results. Three distinct materials namely carbon nanotubes (CNT), graphene, and carbon fiber polylactic acid composite (CF+PLA), and two infill patterns namely honeycomb and rectilinear have been investigated and compared, where it showed that CNT material with honeycomb infill pattern shows better results than graphene and CF+PLA. Additionally, the outcomes of simulation results are compared with CF+PLA specimen created with Creality Ender 3 fused deposition modeling (FDM) printer. The CF+PLA specimen was fabricated according to ASTM D638 having different process parameters. The findings revealed that the tensile strength of carbon allotropes with a honeycomb pattern is increased by 20% when compared to materials made of commercial CF+PLA with a rectilinear pattern. This improvement in strength is attributable to the lower void content and higher layer-to-layer bonding during this process which can improve the components for the aerospace and defense sectors.

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Title: Finite element simulation of additive manufacturing process of carbon allotropes
Authors: Kautilya S. Patel
Susmita D. Solanki
Dhaval B. Shah
S. J. Joshi
K. M. Patel
Publication date: 05-03-2023
Publisher: Springer Paris
Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) / Issue 9/2024
Print ISSN: 1955-2513
Electronic ISSN: 1955-2505
DOI: https://doi.org/10.1007/s12008-023-01221-y

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Finite element simulation of additive manufacturing process of carbon allotropes

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Investigating the influence of single and multicomponent activated fluxes on macrostructure, microstructure, and hardness of ATIG welded SS304

Coupled thermomechanical FE analysis of multi-pass welding in thick pipe

An investigation of the effect of auxiliary pins on mechanical properties of friction stir welded AA2024-T351

Newly applied practices to alleviate design uncertainty: a case study of a design scheme based on the DEMATEL–ANP–VIKOR theory

Development and assessment of African star seed (Chrysophyllum albidum) oil-based cutting fluid in turning AA6061 using Taguchi grey relational approach

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