Multiscale Computational Modeling of 3D Printed Continuous Fiber-Reinforced Composites

Abstract

The printing parameters used during the printing procedure have a significant effect on the mechanical characteristics of 3D printed continuous fiber reinforced composites (3DP-CFRPCs). However, conducting experimental assessments of the material characteristics of 3DP-CFRPCs may require more effort and incur more costs. Computational material modeling may be used as a viable alternative to investigate the behavior of 3DP-CFRPCs under various printing conditions. The current work used material modeling approaches to examine the impact of different printing settings on the elastic characteristics of 3DP-CFRPCs. The inherent flexibility of beads is primarily established by homogenizing the pores within the matrix via the use of the Mori-Tanaka process. Subsequently, the elastic modulus is calculated by using finite element modeling on Representative Volume Element (RVE), which takes into account the microstructure and other printing attributes. An inconsistency was seen in the variation of projected elastic properties across models distinguished by various microstructures, with a more pronounced differentiation observed between intricate and simpler microstructures. Computational modeling has enhanced our understanding of the elastic properties of 3DP-CFRPCs under various printing conditions. Moreover, it has been shown that alterations in printing parameters have diverse impacts on the pliable characteristics of 3DP-CFRPCs. The impact of layer thickness on the mechanical characteristics of 3DP-CFRPCs was determined to be more substantial compared to the effect of printing temperature. The application of offset layup printing techniques enhanced the elastic properties of 3DP-CFRPCs, with the degree of improvement varying based on the orientation. As the level of porosity increased, the influence of pores situated between beads on the overall stiffness of 3DP-CFRPCs gradually diminished, while the impact of matrix pores on the overall stiffness of 3DP-CFRPCs gradually intensified.