Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing
Abstract
:1. Introduction
2. Materials and Methods
2.1. Design of Sandwich Structures
2.2. Design of Wing Leading Edges
2.3. Materials Properties and Manufacturing Conditions
2.4. Mechanical Testing
2.4.1. Compression Tests
2.4.2. Three-Point Bending Tests
2.4.3. Tensile Tests
2.4.4. Impact Tests
3. Results and Discussion
3.1. Compressive Performances of Sandwich Specimens
3.2. Mechanical Characteristics of Sandwich Structures under Three-Point Bending Tests
3.3. Tensile Behavior of Sandwich Specimens
3.4. Strength-to-Mass Ratio Analysis of the Sandwich Specimens
- Based on the compression tests, the sandwich structures with a diamond-celled core presented the best performances;
- Based on the bending tests, the sandwich structures with a diamond-celled core showed the best performances, and the other two core configurations (honeycomb and corrugated) showed similar characteristics;
- Based on the tensile tests, the sandwich structures with a honeycomb core and the sandwich structures with a diamond-cell core showed identical performances, and the sandwich structures with a corrugated core presented the highest performances.
3.5. Impact Testing Properties of Wing Leading Edges
3.6. Results of Finite Element Analyses
4. Conclusions
Author Contributions
Funding
Conflicts of Interest
References
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Compression Test Specimens | Tensile Test Specimens | Three-Point Bending Test Specimens | |
---|---|---|---|
Honeycomb | |||
Diamond-celled | |||
Corrugated |
Honeycomb Core | Diamond-Celled Core | Corrugated Core | |
---|---|---|---|
Wing leading edges |
Mechanical and Thermal Properties | PLA/PHA | Standard |
---|---|---|
Tensile strength [MPa] | 61.5 | ISO 527-1:2019 |
Modulus of elasticity [MPa] | 2960 | ISO 527-1:2019 |
Flexural stress [MPa] | 88.8 | ISO 178:2019 |
Flexural modulus [MPa] | 3295 | ISO 178:2019 |
Impact Strength [kJ/m²] | 30.8 | ISO 179-1:2010 |
Density [g/cm³] | 1.24 | ISO 1183:2019 |
Melting temperature [ºC] | >155 | ISO 3146-C:2000 |
Parameter | Value |
---|---|
Layer height | 0.15 [mm] |
Infill | 100 [%] |
Print speed | 50 [mm/s] |
Travel speed | 200 [mm/s] |
Printing temperature | 200 [°C] |
Building plate temperature | 60 [°C] |
Hotend | 0.4 [mm] |
Sandwich Specimens | Mean (m) | Standard Deviation (s) | Coefficient of Variation (CV)% |
---|---|---|---|
Honeycomb core– Compressive Strength (MPa) | 1.600 | 0.154 | 9.625 |
Diamond-celled core– Compressive Strength (MPa) | 3.000 | 0.244 | 8.133 |
Corrugated core– Compressive Strength (MPa) | 1.000 | 0.077 | 7.700 |
Honeycomb core– Compressive Modulus (GPa) | 0.080 | 0.007 | 8.750 |
Diamond-celled core– Compressive Modulus (GPa) | 0.140 | 0.014 | 10.000 |
Corrugated core– Compressive Modulus (GPa) | 0.074 | 0.004 | 5.405 |
Sandwich Specimens | Mean (m) | Standard Deviation (s) | Coefficient of Variation (CV)% |
---|---|---|---|
Honeycomb core– Bending Strength (MPa) | 8.800 | 0.836 | 9.500 |
Diamond-celled core– Bending Strength (MPa) | 16.200 | 0.908 | 5.604 |
Corrugated core– Bending Strength (MPa) | 5.400 | 0.547 | 10.129 |
Honeycomb core– Bending Modulus (GPa) | 0.500 | 0.035 | 7.000 |
Diamond-celled core– Bending Modulus (GPa) | 1.000 | 0.079 | 7.900 |
Corrugated core– Bending Modulus (GPa) | 0.300 | 0.035 | 11.666 |
Sandwich Specimens | Mean (m) | Standard Deviation (s) | Coefficient of Variation (CV)% |
---|---|---|---|
Honeycomb core– Tensile Strength (MPa) | 2.400 | 0.200 | 8.333 |
Diamond-celled core– Tensile Strength (MPa) | 2.800 | 0.273 | 9.750 |
Corrugated core– Tensile Strength (MPa) | 5.400 | 0.547 | 10.120 |
Honeycomb core– Tensile Modulus (GPa) | 0.360 | 0.031 | 8.611 |
Diamond-celled core– Tensile Modulus (GPa) | 0.400 | 0.028 | 7.000 |
Corrugated core– Tensile Modulus (GPa) | 0.680 | 0.024 | 3.529 |
Wing Leading Edges Specimens | Mean (m) | Standard Deviation (s) | Coefficient of Variation (CV)% |
---|---|---|---|
Honeycomb core– Impact Strength (kJ/m2) | 7.546 | 0.498 | 6.599 |
Diamond-celled core– Impact Strength (kJ/m2) | 13.486 | 0.354 | 2.624 |
Corrugated core– Impact Strength (kJ/m2) | 15.270 | 0.610 | 3.994 |
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Zaharia, S.M.; Enescu, L.A.; Pop, M.A. Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing. Polymers 2020, 12, 1740. https://doi.org/10.3390/polym12081740
Zaharia SM, Enescu LA, Pop MA. Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing. Polymers. 2020; 12(8):1740. https://doi.org/10.3390/polym12081740
Chicago/Turabian StyleZaharia, Sebastian Marian, Larisa Anamaria Enescu, and Mihai Alin Pop. 2020. "Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing" Polymers 12, no. 8: 1740. https://doi.org/10.3390/polym12081740