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Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology

Cellular structures with tailored topologies can be fabricated using additive manufacturing (AM) processes to obtain the desired global and local mechanical properties, such as stiffness and energy absorption. Lattice structures usually fail from the sharp edges owing to the high stress concentratio...

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Autores principales: Nazir, Aamer, Arshad, Ahmad-Bin, Hsu, Chi-Pin, Jeng, Jeng-Ywan
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8123134/
https://www.ncbi.nlm.nih.gov/pubmed/33923348
http://dx.doi.org/10.3390/ma14092194
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author Nazir, Aamer
Arshad, Ahmad-Bin
Hsu, Chi-Pin
Jeng, Jeng-Ywan
author_facet Nazir, Aamer
Arshad, Ahmad-Bin
Hsu, Chi-Pin
Jeng, Jeng-Ywan
author_sort Nazir, Aamer
collection PubMed
description Cellular structures with tailored topologies can be fabricated using additive manufacturing (AM) processes to obtain the desired global and local mechanical properties, such as stiffness and energy absorption. Lattice structures usually fail from the sharp edges owing to the high stress concentration and residual stress. Therefore, it is crucial to analyze the failure mechanism of lattice structures to improve the mechanical properties. In this study, several lattice topologies with fillets were designed, and the effects of the fillets on the stiffness, energy absorption, energy return, and energy loss of an open-cell lattice structure were investigated at a constant relative density. A recently developed high-speed AM multi-jet fusion technology was employed to fabricate lattice samples with two different unit cell sizes. Nonlinear simulations using ANSYS software were performed to investigate the mechanical properties of the samples. Experimental compression and loading–unloading tests were conducted to validate the simulation results. The results showed that the stiffness and energy absorption of the lattice structures can be improved significantly by the addition of fillets and/or vertical struts, which also influence other properties such as the failure mechanism and compliance. By adding the fillets, the failure location can be shifted from the sharp edges or joints to other regions of the lattice structure, as observed by comparing the failure mechanisms of type B and C structures with that of the type A structure (without fillets). The results of this study suggest that AM software designers should consider filleted corners when developing algorithms for generating various types of lattice structures automatically. Additionally, it was found that the accumulation of unsintered powder in the sharp corners of lattice geometries can also be minimized by the addition of fillets to convert the sharp corners to curved edges.
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spelling pubmed-81231342021-05-16 Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology Nazir, Aamer Arshad, Ahmad-Bin Hsu, Chi-Pin Jeng, Jeng-Ywan Materials (Basel) Article Cellular structures with tailored topologies can be fabricated using additive manufacturing (AM) processes to obtain the desired global and local mechanical properties, such as stiffness and energy absorption. Lattice structures usually fail from the sharp edges owing to the high stress concentration and residual stress. Therefore, it is crucial to analyze the failure mechanism of lattice structures to improve the mechanical properties. In this study, several lattice topologies with fillets were designed, and the effects of the fillets on the stiffness, energy absorption, energy return, and energy loss of an open-cell lattice structure were investigated at a constant relative density. A recently developed high-speed AM multi-jet fusion technology was employed to fabricate lattice samples with two different unit cell sizes. Nonlinear simulations using ANSYS software were performed to investigate the mechanical properties of the samples. Experimental compression and loading–unloading tests were conducted to validate the simulation results. The results showed that the stiffness and energy absorption of the lattice structures can be improved significantly by the addition of fillets and/or vertical struts, which also influence other properties such as the failure mechanism and compliance. By adding the fillets, the failure location can be shifted from the sharp edges or joints to other regions of the lattice structure, as observed by comparing the failure mechanisms of type B and C structures with that of the type A structure (without fillets). The results of this study suggest that AM software designers should consider filleted corners when developing algorithms for generating various types of lattice structures automatically. Additionally, it was found that the accumulation of unsintered powder in the sharp corners of lattice geometries can also be minimized by the addition of fillets to convert the sharp corners to curved edges. MDPI 2021-04-24 /pmc/articles/PMC8123134/ /pubmed/33923348 http://dx.doi.org/10.3390/ma14092194 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Nazir, Aamer
Arshad, Ahmad-Bin
Hsu, Chi-Pin
Jeng, Jeng-Ywan
Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title_full Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title_fullStr Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title_full_unstemmed Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title_short Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
title_sort effect of fillets on mechanical properties of lattice structures fabricated using multi-jet fusion technology
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8123134/
https://www.ncbi.nlm.nih.gov/pubmed/33923348
http://dx.doi.org/10.3390/ma14092194
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