5 aN , ANALYSIS OF ADDITIVELY MANUFACTURED ? LATTICE STRUCTURES AND VALIDATION USING EXPERIMENTAL AND SIMULATION METHODS A Mid-Term Evaluation Report submitted in partial fulfillment of the requirements for the award of the degree of Master of Engineering In Mechanical Engineering (Specialization in Design for Manufacture) Submitted by M.J.V.R.SAI RAM 1005-18-765311 Under Guidance of Dr. L. Siva Rama Krishna Associate Professor ——~S= 2019-2020 DEPARTMENT OF MECHANICAL ENGINEERING UNIVERSITY COLLEGE OF ENGINEERING (AUTONOMOUS) OSMANIA UNIVERSITY, HYDERABAD, TELANGANA, INDIA-500027. —— 1= = eeovvwesseusteuwvs»ew»vwus se ewww * ve ve ABSTRACT Additive manufacturing (AM) enables time and cost savings in the product development process. It has great potential in the manufacturing of lighter parts or tools by the embedding of cellular/lattice structures that consume less material while still distributing the necessary strength. 3D printing offers unique capability to manufacture structural shapes and sizes that are not practical with the conventional manufacturing methods. A lattice structure consisting of beam element, where most material carries load in tension is likely to be most efficient and hence has highest potential of being lightest shape for the given material. Lattice structures are known for their high strength-to-weight ratio, multiple functionalities, Lightweight, stiffness, and energy absorption capabilities and potential applications in aerospace, automobile, and biomedical industry. In this work it is proposed to fabricate four design lattice structure namely DIAMOND, DODE, CROSS and DIAGONALS. A comparative study is proposed to be done on four lattice structures mentioned above. The aim of proposed work is to find the mechanical behavior of additively manufactured lattice structures of different configurations. Four lattice structure designs were selected for comparison: DIAMOND, DODE, CROSS and DIAGONALS. Samples of all four polymer designs were prepared using POLYJET additive process. The VeroClear. The stiffness, failure loads, and energy absorption material used for printin behaviors of all four configurations were determined by performing compression test. Based on the simulation and experimental results, stress-strain relationship and failure were determined.ewes . ~~~ eee verve wee we wee wurvruervuwewews Abstract... List of Contents... List of Figures... CHAPTER-1 Ml 12 13 La Ls 16 17 18 19 CHAPTER-2 CHAPTER-3 31 CHAPTER-4 41 42 43 CHAPTER-5 5.1 5.2 CHAPTER-6 REFERENCES.... Proposed Methodology. LIST OF CONTENTS Introduction. Additive Manufacturing, Classification OF Additive Manufacturing Systems............0+-0405 Polyjet Printing... Advantages of Polyjet 3D printers. Cellular Structures.......00.0 Types of Cellular Structures. Benefits and Applications... Optimization of Lattice Structure. Compression Test... Literature Review.. Problem Statement. Objectives... Selection of Lattice Structures. Fabrication using polyjet printer... 4.2.1 Specifications of PIP...........+. Experimental Analysis........00000000 4.3.1 Compression Test. Work Plan. Work Done... Work to be done. Results and Discussions..........eoeeeuevsevsvsess'* * * aa eovveove LIST OF FIGURES Figure 1: Classification of additive manufacturing technologies. Figure 2: The main components of a PolyJet 3D printer... Figure 3: Polyjet object30 3d printer. Figure 4: Object30 3D printer specifications...... Figure 5: Examples of naturally occurring cellular structures. (a) Human bone under SEM. (b) Honeycomb structure. (c) Fungimushrooms. (d) Voronoi structure in bubbles. (c) Wing of a dragonfly. (f) Leaf structure... 12 Figure 6: Applications of cellular structures. Figure 7: optimization of lattice structures. Figure 8: Compression test setup.... Figure 9: Diamond and Dode lattice structures... Figure 10: Diagonal and Cross lattice structures. ..CHAPTER-1 INTRODUCTION 1.1 Additive Manufacturing Additive Manufacturing is the generalized term popularly known as Rapid Prototyping (RP) also known as 3D printing, Additive Manufacturing (AM), refers to the process used to generate a three-dimensional computer aided design (3D CAD) that can be fabricated directly without any need for process planning. Additive manufacturing creates an object by addition of material in the form of thin layers continuously, each layer is a thin cross-section of part derived from a CAD model. Objects can be of almost any shape or geometry can be produced using AM technology. Additive manufacturing (AM) technique, commonly known as 3D printing technique, offers great possibi jes for fabricating parts with high complexity and customizability such as cellular structures which are difficult, tedious and time consuming, if not impossible, to produce us ng conventional manufacturing processes. The concept of the cellular structures, including foams, honeycombs, lattices, and similar constructions, comes from keeping material only in the vital res ns of'a part to attain a lightweight structure while maintaining the high specific mechanical properties such as strength and energy absorption. Lattice-based cellular structures offer inherent advantages over foams due to their ability to provide light- weight and stronger materials. Additive Manufacturing's carliest applications have been on the tool room end of the manufacturing spectrum, For example, rapid prototyping was one of the ea st additive variants and its mission was to reduce the lead time and cost of developing prototypes of new parts and de es, which was earlier only done with subtractive tool room methods such as CNC milling and turing, and precision grinding, far more accurate than 3d printing with accuracy down to 0.00005" and creating better quality parts faster, but sometimes too expensive for low accuracy prototype parts. 1.2 Classification of Additive Manufacturing systems RP processes may be divided broadly into those involving the addition of material and those involving its removal. According to Kruth material accretion processes may be divided by the state of the prototype material before part formation, namely, liquid, powder or solid sheets. 5« SP = tm ek = el ium): tue in hom hee cl el te hel Me Liquid-based processes may entail the solidification of a resin on contact with a laser, the solidification of an electro setting fluid, or the melting and subsequent solidification of the prototype material. Processes using powders aggregate them either with a laser or by the selective application of binding agents. Those processes which use solid sheets may be classified according to whether the sheets are bonded with a laser or with an adhesive. Figure 1 shows Kruth's classification which has been adapted to include new processes. ‘AM processes iain) wits po! 7 = 4 (om) xe ( orca Fused Stereo Deposition | | titho- ‘raphy Melting Polymerisation Pre Polyiet a0 printing | | srotat Melting [a a TE Ea [= Selective a x | Laminated laser laser oe beam engineered net snteng || meting | [ et | | meting shaping Figure 1: Classification of additive nuanutacturing technologies There are numerous ways to classify AM technologies. A popular approach is to classify to collect processes together according to the type of raw material input into which the material that all AM systems can be easily categorized into (1) Liquid-based (2) Solid-based and (3) Powder-based. 1.2.1 Liquid-Based Liquid-based AM system the raw material used is in the form of liquid later which will be converted into solid by a common process called curing to obtain a product. The following ‘AM systems fall into this category: 1, Stereolithography Apparatus (SLA) 2. Solid Ground Curing (SGC)o:o V7cv oe 7:7" "OO 3. Solid Creation System (SCS) 4, Solid Object Ultraviolet-Laser Printer 1.3 Polyjet printing PolyJet is a 3D printing technology that builds parts by jetting thousands of photopolymer droplets onto a build platform and solidifying them with a UV light. It's one of the fastest and most accurate 3D printing technologies currently available. The anatomy and printing process of a PolyJet 3D printer are the same as for a material jetting 3D printer. yen Cover Figure 2: The main componcnts of a PolyJet 3D printer From fig.6. PolyJet printers consist of a material contail cr, a build platform (and its elevator), and a carriage on which UV lights and jetting print heads are mounted. Before printing begins, photopolymer resin must be poured into the material container and heated. This allows the substance to reach the desired viscosity. ‘The printing process starts with the carriage moving across the X-axis, across the build platform. As it moves, the print heads selectively jet the resin, in the form of droplets, onto the build platform. Immediately after they're jetted, the UV lights cure them into an ever- growing solid. ‘As there are multiple print heads, different materials can be printed at once. An example application of this functionality is a part requiring supports, where the support material builds up at the same time as the main material.After a single layer is complete, the build platform 7Chapter 2 LITERATURE REVIEW U.N. Gandhi.et.al [1] studied the methodology to design, optimize and evaluate periodic ed cellular structures, which can be manufactured using 3D printing. A user- lattice-bas friendly design framework for lattice cellular structures is developed using a size optimization algorithm. Also a method to develop 3D cellular geometry for use in non-linear introduced. The 3D model for the optimized lattice conducted to predict the performance. nulations. Material properties finite element analy 4 3D printing structure is built and non-linear finite element study Physical parts are 3D printed and t for the ested to compare with the s g reverse engineerin; D printed parts are determined for the finite element study us ‘of actual measured data at coupon level. Christiane Beyer.etaal [2] dosign and analyzed the lattice structure geometry can be manipulated to deliver the level of performance required of the part. The development and ificant interest of si research of different cell and lattice structures for lightweight desi ‘The research not only includes analysis of de for realizing the full potential of AM technolog but it also involv: existing software tools to design and optimize cell structur olid foundation of an consideration of different unit cell structures, This paper gives experimental analysis of additive manufactured parts with diverse unit cell structures in compression and flexural tests, Although the research also includes theoretical finite element analysis (FEA) of the models, the results are not considered here. As an introduction, the 5 the basics of stress and strain relationship and summarizes the test paper briefly expla procedure and methods. The tests concentrate primarily on the analysis of 3D printed polymer parts manufactured using Polylet technology. The results show the behavior of test specimens with different cell structures under compression and bending load, Mohammed Al Rifaic.et.al [3] focused on the comp jon behavior of additively of different manufactured or three-dimensional printed polymer lattice _structu configurations. The latice structure based on the body-centered cubic unit cell was modified by adding vertical struts in different arrangements to ereate three additional configurations, Four lattice structure designs were selected for comparison: the basie unit cell (body centered cubic), body centered cubie with vertical struts added to all nodes in the lattice, body centered cubic with vertical struts added to alternate nodes in the lattice, and body centered cubic with 16S CASS weewuw . ewvrvevwewwvwvweveWwewseeeeseseseeoee ee & ee Chapter 3 PROBLEM STATEMENT A product is optimized to reduce its weight and material by using lattice structures without Latti weight ratio, multiple functionalities, Lightweight, stiffness, and energy absorption structures are known for their high strength-to- change in its mechanical properties capabilities and potential applications in acrospace, automobile, and biomedical industry. The scope of the experiment was to predict the mechanical behavior of additively manufactured lattice structures. In this work it is proposed to fabricate four design lattice structure namely DIAMOND, DODE, CROSS and DIAGONALS. A comparative study is proposed to be done on four lattice structures mentioned above. The material used for printing is VeroClear and Samples of all four polymer designs were prepared using POLYIET additive process. The stiffness, failure loads, and energy absorption behaviors of all four configurations were determined by performing compression test. Based on the simulation and experimental results, stress-strain relationship and failure were determined. 3.1 Objectives The objective of this research is to compare and evaluate the mechanical properties of four different lattice structures namely DIAMOND, DODE, DIAGONAL and CROSS. 1. Design of four different lattice structures. Conversion of CAD files to .STL files and 3D print of lattice structure using polyjet additive manufacturing process. Experiment and Simulation tests to be perform on the printed lattice structures. 4. Compare and evaluate the experiment and simulation results as per the required parameters. 19ue ou @ weweeusese ew . _o"Tcovvr-rorvruveewewerewersewrmrewrmre ee ee & & PROPOSED METHODOLOGY Collection of Data Selection of Lattice Structu: Chapter 4 20Chapter 5 5.1 Work done 1. From literature survey, important lattice structures have been selected in order to evaluate, 2. Four lat cross. Selected the polyjet printer to fabricate the lattice structures. ce structures were selected namely, DIAMOND, DODE, DIADONAL and VeroClear material is used in polyjet printer. Selected ANSYS a: Mechanical test has been selected to evaluate the experimental results, mulation software to evaluate the simulation results. 5.2 Work to be done Modeling of four different lattice structures. Mechanical test place to be identified. Fabricate the lattice structures on polyjet printer. s ‘Comparison of experimental and simulation results. vbuvsees o 23 eevee ™sae wueuwvwveuwvveve vv ~ewwvrwewewrvrvrvwrvuevevvvvuv vw Chapter 6 6.1 Results and Discussions It is expected to find the compressive strength of each lattice structures mentioned above. The load and displacement parameters of each lattice structures were determined. I is expected to give lattice to functionally graded materials where strength is required. A comparative study was examined on the experimental and simulation results. ion results, then the results are If the experimental results are 90% closer to the simu said to be optimum. nd energy absorption behaviors of all four configurations The stiffness, failure loads, were determined by performing experimental and simulation tests Based on the simulation and experimental results, stress-strain relationship and failure, were determined 24wevwvvevvevvvevevuvuv vee eww eee rere rr REFERENCES [1]. U.N. Gandhi, R. M. Gorguluarslan, Y. Song, R. Mandapati, “DESIGNING LATTICE STRUCTURES FOR 3D PRINTING” , Toyota Research Institute of North America, Ana Arbor, Ml, 48104. [2]. Christiane Beyer, Dustin Figueroa, “Design and Analysis of Lattice Structures for Additive Manufacturing” , Journal of manufacturing science and engineering. Dec 2016, Vel, 138/121014-1 [3]. Mohammed AI Rifaie, Ahsan Mian and Raghavan Srinivasan, “Compression behavior of . Journal of materials... Design and three-dimensional printed polymer lattice structures applications, Mar 2018. [4]. Aamer Nazir, Jeng-Ywan Jeng, “Buckling behavior of additively manufactured cellular columns: Experimental and simulation validation”, Elsevier Inc/2019. [5]. Aamer Nazir, Ahmad Bin Arshad and Jeng-Ywan Jeng, ~ Buckling and Post-Buckling 1g Additive Behavior of Uniform and Variable-Density Lattice Columns Fabricated Manufacturing”, MDPI journal/2019, 12, 39. [6]. Mark Helou & Sami Kara , “ Design, analysis and manufacturing of lattice structures: an overview “*, Intemational Journal of Computer Integrated Manufacturing 2017 [7]. Aamer Nazir & Kalayu Mekonen Abate & Ajeet Kumar & Jeng-Ywan Jeng, n, optimization, and additive manufacturing of cellular the-art review on types, des structures” , The International Journal of Advanced Manufacturing Technology/2019.