Publication: A comparative tensile analysis of 3D printing with simulation for aerospace-grade material and parametric study on 3D printing variables that impact time and material consumption
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Date
2023-07-25
Authors
Chee, Hon Kit
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Abstract
The study utilized additive manufacturing (AM) through layer-by-layer fabrication, which transforms digital designs into physical objects. The utilization of
3D printing technology greatly enhances the capabilities for fabricating lightweight components, intricate and advanced geometries, as well as cost effective components which might be feasible to adopt within the aerospace industry. The Taguchi analysis with an L16b orthogonal array was employed to analyze
the effects of various parameters including infill density, infill structure, print speed, layer height, and bed temperature. The investigation revealed that print speed exerted the most substantial influence on printing time. This underscored the importance of optimizing print speed to ensure efficient and time-effective 3D printing. In terms of material usage and tensile strength, infill density emerged as the most influential factor. Moreover, higher infill densities were found to enhance the tensile strength of the 3D printed specimens while infill density parameter is crucial for striking a balance between material usage and achieving desirable mechanical properties in the printed components. A comparison was made between 3D printed PLA carbon fiber composite specimens and simulations using Epoxy Carbon UD Prepreg and Epoxy Carbon UD Wet materials. The results demonstrated that conventional fiber materials used in aerospace applications exhibited significantly higher tensile strength (64.456 GPa) compared to the 3D printed PLA carbon fiber composite (31.751 MPa). The difference in tensile strength can be attributed to variations in material properties and composition, with the conventional fiber materials being specifically engineered and optimized for aerospace applications. 3D printing technology has shown remarkable potential in various aspects of aerospace applications, its adoption as a replacement for
conventional manufacturing methods is still a considerable distance away. The results of this study demonstrate that although 3D printing offers advantages such as customization, reduced tooling costs, and the ability to fabricate complex geometries, there are limitations to its mechanical performance compared to conventional fiber materials specifically engineered for aerospace applications.