Engineering Commons^™

Estimation Of The Fatigue Life Of Additively Manufactured Metallic Components Using Modified Strain Life Parameters Based On Surface Roughness, Peter Grohs

Masters Theses

In this study, a method is developed to estimate the effects of surface roughness on the fatigue life of additively manufactured titanium Ti6Al4V, aluminum 7075–T6, and steel 4340 alloys through modified strain life parameters using finite element analysis (FEA). This method is highly beneficial to the fatigue analysis of as-built additively manufactured metal components, which possess rough surfaces that reduce fatigue life significantly but are challenging to analyze directly using finite element simulation because of complex geometries, i.e., modeling an exact surface profile is arduous.

An effective stress concentration factor, incorporating roughness data, is defined to quantify their effects on …

Material Characterization And Fracture Prediction Of Fdm Printed Parts, Sanchita Sheth

Mechanical and Aerospace Engineering Theses

In order to take advantage of the design freedom that Additive Manufacturing offers, most applications require reliable material characterization. This can ensure that a design performs within its environment and life requirements. This work discusses two models. One investigates the raster angle dependency of stiffness properties and the other numerically predicts fracture in Fused Deposition Modeling (FDM) printed polymer parts. Pre-processing of FDM geometry was done in Abaqus CAE (SIMULIA TM). FEA and post-processing was done in BSAM, which is a damage prediction software developed for composites. BSAM uses a regularized extended finite element approach of Discrete Damage Modeling. In …

Static Response Calibration Of 3d Printed Thin Walled Structures Using Fused Deposition Modelling, Akhilesh Ravindra Kulkarni

Mechanical and Aerospace Engineering Theses

3-D printing has enabled flexible, tool-less fabrication that yields numerous benefits. One benefit is unique and complex structural arrangements that increase design freedom to minimize weight. Such arrangements can be guided by advanced topology, shape, and sizing optimization tools using appropriate process constraints to ensure a printable design and can include highly integrated structural details such as stiffeners, flanges, frames, and other connections. 3D printing thin wall aircraft structures presents challenges for material and structural characterization. 3D printing enables integrated structural details, each detail is affected by the print process capability to fabricate the local geometry and deviations from designed …

Characterization Of Thermo-Mechanical Properties Of Copper Nano-Particles Infused Acrylonitrile Butadiene Styrene (Abs)- 3d Printed Specimens, Viswajit Talluru

Mechanical and Aerospace Engineering Theses

Now a days the use of metal nanoparticle infused polymer is becoming widespread, since the development of polymer with enhanced thermal properties are being used for the growth of electronic packaging industry. In this study, copper nanoparticles are mixed with the Acrylonitrile Butadiene Styrene (ABS) thermoplastic in varying mass proportions, to observe the changes in thermal and structural properties of ABS. As expected, the extruded wire with high nano-particle concentration exhibited much higher thermal conductivity than its raw ABS form. For the case of 2% copper nanoparticle infused ABS using one dimensional steady state heat flux method though extrude wire …