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Virtual and Physical Prototyping

ISSN: 1745-2759 (Print) 1745-2767 (Online) Journal homepage: https://www.tandfonline.com/loi/nvpp20

Compressive properties of 3D printed auxetic


structures: experimental and numerical studies

Amer Alomarah, Syed H. Masood, Igor Sbarski, Batool Faisal, Zhanyuan Gao
& Dong Ruan

To cite this article: Amer Alomarah, Syed H. Masood, Igor Sbarski, Batool Faisal, Zhanyuan Gao
& Dong Ruan (2019): Compressive properties of 3D printed auxetic structures: experimental and
numerical studies, Virtual and Physical Prototyping, DOI: 10.1080/17452759.2019.1644184

To link to this article: https://doi.org/10.1080/17452759.2019.1644184

Published online: 23 Jul 2019.

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VIRTUAL AND PHYSICAL PROTOTYPING
https://doi.org/10.1080/17452759.2019.1644184

Compressive properties of 3D printed auxetic structures: experimental and


numerical studies
a,b
Amer Alomarah , Syed H. Masooda, Igor Sbarskia, Batool Faisalb, Zhanyuan Gaoc and Dong Ruan a

a
Faculty of Science, Engineering and Technology, Swinburne University of Technology, Hawthorn, Australia; bMechanical engineering
department, Faculty of Engineering, Wasit University, Al-Kut, Iraq; cTianjin Key Laboratory of Civil Structure Protection and Reinforcement,
Tianjin Chengjian University, People’s Republic of China

ABSTRACT ARTICLE HISTORY


Metamaterials that exhibit negative Poisson’s ratio (NPR) are known as auxetics. They laterally Received 2 May 2019
expand or contract when they are axially tensioned or compressed. A re–entrant chiral auxetic Accepted 12 July 2019
structure (RCA) is a recently developed structure, which combines the topological features of re–
KEYWORDS
entrant and chiral honeycombs. Comparative study between the RCA structure and popular Auxetic; energy absorption;
benchmarks subjected to uniaxial compression has been conducted experimentally and in–plane compression; Multi
numerically. Specimens have been fabricated from polyamide12 (PA12) using Multi Jet Fusion Jet Fusion (MJF); negative
(MJF). Numerical models have been developed using ABAQUS/Explicit and verified by the Poisson’s ratio; re–entrant
experiments. The experimental measurements manifest the high accuracy of the MJF process to chiral auxetic (RCA) structure
produce robust components with precise details. It has been found that the RCA structure
outperforms the other types of honeycombs in terms of strength and specific energy absorption
when loaded in the Y direction, while only the tetrachiral honeycomb surpasses the RCA
structure in terms of specific energy absorption when loaded in the X direction. The auxeticity
(NPR) of the RCA structure compressed in the Y direction was larger than that of the other
honeycombs. Numerical models have been employed to study the effects of friction and the
number of cells on the mechanical response of the RCA structure.

1. Introduction
2007), sound absorbers (Scarpa, Bullough, and Lumley
Cellular structures have attracted great attention and 2004), magnetics (Abramovitch et al. 2010) and medical
been increasingly used in various applications due to industries (Wang et al. 2016; Yang, Vora, and Chang
their lightweight and good mechanical properties 2018). The auxetic behaviour improves the mechanical
(Gibson and Ashby 1997; Funkel et al. 2019; Shen, Lu, properties especially the energy absorption of structures.
and Ruan 2010). Ongoing developments in cellular struc- The reasons are that when an auxetic structure is com-
tures have led to more novel auxetic structures. The term pressed axially, it contracts laterally and becomes more
‘auxetic’ was introduced in 1991 for the first time (Evans compact resulting in higher stress and greater specific
1991). The novelty of auxetic structures comes from energy absorption (Alomarah et al. 2019). Researchers
their topological features, which display counterintuitive have paid great attentions to the mechanical properties
response to the applied load. Auxetic structures contract of auxetic structures. Mechanical properties of the re–
laterally when compressed and expand laterally when entrant and the conventional hexagonal honeycombs
stretched, exhibiting negative Poisson’s ratio (NPR) (Li, have been examined and compared (Hou, Deng, and
Dong, and Lakes 2013). In fact, the auxetic effect have Zhang 2016; Liu et al. 2016). Results revealed that due to
led to special properties including better indentation the auxetic effect, the re–entrant honeycomb exhibited
resistance, shear modulus, fracture toughness, variable a higher ability to absorb energy than the hexagonal hon-
permeability and energy absorption (Choi and Lakes eycomb. A new auxetic structure was proposed, which
1996; Assidi and Ganghoffer 2012; Alderson et al. 2001). combined the topological features of the star–shaped
These attractive properties have offered various appli- and the re–entrant honeycombs (RSH) (Wang et al.
cations of auxetic structures such as cores for sandwich 2019). The energy absorption and the auxeticity of the
panels (Imbalzano et al. 2017), smart filters (Alderson proposed structure were improved compared with tra-
et al. 2000), mechanical absorbers (Bezazi and Scarpa ditional re–entrant honeycomb. Quasi-static and fatigue

CONTACT Dong Ruan druan@swin.edu.au Faculty of Science, Engineering and Technology, Swinburne University of Technology, Hawthorn, VIC 3122,
Australia
© 2019 Informa UK Limited, trading as Taylor & Francis Group
2 A. ALOMARAH ET AL.

properties of auxetic and conventional thermoplastic PU entrant and chiral honeycombs (Alomarah, Ruan, and
foams were investigated (Bezazi and Scarpa 2009). Find- Masood 2018a, 2018b). Therefore, re–entrant, tetrachiral
ings confirmed better mechanical resilience and signifi- and anti–tetrachiral honeycombs have also been investi-
cant energy absorption capability. gated in this study for comparison. A 2D sketch and 3D
Different auxetic structures have been reported such CAD model of the RCA structure, re–entrant honeycomb,
as re–entrant honeycomb (Evans, Alderson, and Christian tetrachiral honeycomb and anti–tetrachiral honeycomb
1995; Alomarah et al. 2017), rotating rigid or semi–rigid are depicted in Figure 1(a–h), respectively. In RCA unit
units (Grima and Evans 2000; Grima, Alderson, and cells (Figure 1(a)), H, L₁ and L₂ denote the lengths of ver-
Evans 2014), star–shaped (Grima et al. 2005), double tical, inclined and horizontal walls respectively, while r is
arrowhead honeycombs (Qiao and Chen 2015), and the outer radius of cylinders. The inclination angle
chiral honeycombs (Prall and Lakes 1997). Recently, a between the vertical (H ) walls and the inclined (L₁)
new auxetic structure named re–entrant chiral auxetic walls is θ₀. For re-entrant honeycombs, H, L₁, θ₀ and t₁
(RCA) structure has been proposed, which incorporated are vertical wall length, inclined wall length, inclination
the chiral features in a re-entrant honeycomb (Alomarah, angle and wall thickness, respectively. For tetrachiral
Ruan, and Masood 2018a, 2018b). Since the RCA unit cell and anti–tetrachiral honeycombs, H, r and t₁ are wall
combines the topological features of both chiral and re- length, cylinder radius and wall thickness, respectively.
entrant honeycombs, the auxetic behaviour of the RCA All walls and cylinders are designed to have the same
structure comes from both factors. Firstly, the re– in–plane (t₁) and out–of–plane (t₂) thicknesses. From
entrant feature leads to the inward or outward move- Figure 1, it is clear that the connections between walls
ments of the inclined walls when they are compressed and cylinders of the RCA structure are the same as that
or tensioned, respectively. Secondly, the chiral features for the chiral honeycomb (red walls) and the anti–chiral
results in wrapping and unwrapping of ligaments honeycomb (green walls). For comparison, all four
around the rotated cylinders. Our previous work (Alo- types of specimens have identical global in–plane
marah et al. 2018b) studied both the RCA structure and (80 mm × 64 mm) and out–of–plane (t₂=30 mm) dimen-
the re–entrant honeycomb with similar geometrical par- sions. The dimensions of designed unit cells and global
ameters subjected to quasi–static tensile loading. Results dimensions of specimens are listed in Table 1.
showed that the RCA structure outperformed the re–
entrant honeycomb in terms of stress and auxetic behav-
2.2. Additively manufactured specimens
iour in the X direction. These interesting properties trig-
gered the current investigation of the compressive A 3D printing process, Multi Jet Fusion (MJF), was used
properties (stress–strain curves, energy absorption and to fabricate the experimental specimens. MJF is an addi-
auxetic behaviour) of the RCA structure. tive manufacturing technique through which physical
In this study, the compressive properties of the RCA components are fabricated layer–by–layer. HP Jet
structure and three common auxetic honeycombs: re– Fusion 3D 4200 Printer was employed to print the
entrant, tetrachiral and anti–tetrachiral, have been inves- experimental specimens of each type from polyamide
tigated and compared. Uniaxial quasi–static compressive 12 (HP PA12). This 3D printing process begins with
tests have been carried out in two in–plane directions (X spreading a thin layer of material powder onto a build
and Y) for non–symmetric structures (RCA and re– platform of the printer. A thermally reactive black ink
entrant), and in one in–plane direction for the symmetric (contains fusing agents) is jetted on the powder bed
structures (tetrachiral and anti–tetrachiral). Finite where the particles are meant to fuse together. Accurate
element (FE) models have also been developed using details and high resolution are achieved by applying
ABAQUS/Explicit and verified by the experimental data. non–thermally reactive ink (contains detailing agents)
The aims of the current study are to investigate the around the contour of the component. Subsequently,
mechanical response of the RCA structure and compare the entire layer of powder bed is heated using infrared
it with that of other popular auxetic honeycombs lamps whose heat distributes evenly. The thermal reac-
reported in the literature. tion between the fusing agent and material powder
causes the powder to be selectively fused. More
detailed description of 3D printing using MJF technique
2. Experiments can be found in (Alomarah et al. 2019). Four RCA speci-
mens, four re–entrant specimens, two tetrachiral speci-
2.1. Specimens geometry
mens and two anti-tetrachiral specimens were printed.
The unit cell of the re–entrant chiral auxetic (RCA) struc- Figure 2 shows isometric and front views of the
ture has been designed based on the geometries of re– printed specimens of each type.
VIRTUAL AND PHYSICAL PROTOTYPING 3

Figure 1 . Topologies of different cellular auxetic structures investigated in this study: 2D sketches of (a) RCA structure; (b) re–entrant
honeycomb; (c) tetrachiral honeycomb; (d) anti–tetrachiral honeycomb; 3D CAD models of (e) RCA structure; (f) re–entrant honeycomb;
(g) tetrachiral honeycomb; (h) anti–tetrachiral honeycomb.

After printing, an air jet cleaning was employed to 2.3. Experimental testing
remove all loose powder (non–fused PA12 powder). A
2.3.1. Properties of the parent material
digital vernier caliper was then used to measure the
In order to investigate the properties of the parent
dimensions of the unit cells and the global dimensions
material (HP PA12), four tensile samples (type IV) were
of the printed specimens. Four random locations were
printed and tested according to ASTM standards D638
chosen on each specimen and an average value was
(A Standard 2014). Figure 4(a) shows CAD model of a
taken as the dimension. The measured dimensions of
tensile sample with the key dimensions illustrated. It
the printed specimens were found to be the same as
should be mentioned that the four samples were
those designed ones quoted in Table 1, indicating high
printed with a thickness of 3.4 mm. The effect of building
accuracy and capability of the MJF process. Moreover,
(layer up) direction of the printed parts using MJF
to further examine the dimensions of the printed speci-
process was experimentally investigated (O’Connor,
mens before testing, an optical stereomicroscope (Leica
Dickson, and Dowling 2018) and the results showed
MZ6) was used. Figure 3 depicts the measured dimen-
that mechanical properties varied slightly (less than 8%
sions of the unit cells of the re–entrant honeycomb
and 4% for the tensile modulus and tensile strength,
and the RCA structure, which confirmed the measure-
respectively) in the three (X, Y and Z) directions. There-
ments made by the vernier caliper. The masses of the
fore, the properties of the parent material were regarded
printed specimens were measured using a digital scale.
as isotropic and tensile samples were printed in one
The density of each specimen was calculated by dividing
direction only. Quasi–static tensile tests were carried
the measured mass by the volume, 80 × 64 × 30 mm³.
out at 0.05 mm/s using a Zwick/Z010 machine. The
The densities of the printed specimens were 280, 300,
quasi–static engineering stress (s) was calculated as
240 and 240 kg/m³ for the RCA, re–entrant, tetrachiral
the ratio of the measured instantaneous force (F ) over
and anti–tetrachiral, respectively.

Table 1. Dimensions of cells and global dimensions of specimens (Note: letters X and Y denote loading directions)
Unit cells Specimens
Structures H (mm) L₁ (mm) L₂ (mm) θ (°) r (mm) t1 (mm) t2 (mm) X (mm) Y (mm)
RCA-X 8 4.5 4.5 50 1.5 0.8 30 64 80
RCA-Y 8 4.5 4.5 50 1.5 0.8 30 80 64
Re-entrant-X 8 4.5 — 50 — 0.8 30 64 80
Re-entrant-Y 8 4.5 — 50 — 0.8 30 80 64
Tetrachiral 8 — — —- 1.5 0.8 30 64 80
Anti-tetrachiral 8 — — —- 1.5 0.8 30 64 80
4 A. ALOMARAH ET AL.

Figure 2. 3D printed auxetic specimens from (HP PA12) using MJF process: isometric view of (a) RCA structure; (b) re–entrant honey-
comb; (c) tetrachiral honeycomb; (d) anti–tetrachiral honeycomb; front view of (e) RCA structure; (f) re–entrant honeycomb; (g) tetra-
chiral honeycomb; (h) anti–tetrachiral honeycomb.

the original cross–sectional area of the tensile samples to yield (σ = 38 MPa), the material behaviour of PA 12
(3.4 × 6 mm2). While engineering strain was calculated can be describe as strain hardening. From Figure 4(b),
as the ratio of the instantaneous displacement over the a remarkable increase of the stress in the plateau
original gauge length (25 mm). The true stress and true regime was observed to reach the maximum value (σ
strain were calculated using Equations (1) and (2), = 56.2 MPa) at approximately 0.12 axial strain. Afterward,
respectively. Figure 4(b) shows the corresponding true the stress keep consistent up to the necking in the all
stress–strain curves of the four repeated tests. It can be tensile samples but sample 4. This might be due to
seen that all tested samples manifest similar flow defects in this sample. The average values of the calcu-
stress. The average values of the measured elastic prop- lated plastic properties up to the strain of the
erties obtained from the four tensile tests and the value maximum tensile strength of the four tensile samples
of Poisson’s ratio (Habib et al. 2017) are summarised in are summarised in Table 2. The calculated material prop-
Table 2. After the elastic regime where material starts erties (elastic and plastic) were used in the finite element

Figure 3. Optical photographs showing the measured dimensions of geometrical parameters of an untested: (a) re–entrant specimen;
(b) RCA specimen.
VIRTUAL AND PHYSICAL PROTOTYPING 5

central region of each specimen as depicted in Figure


5. The nominal strain was defined to be ɛ = δ/V, where
δ is the change in displacement between the machine
platens, and V is the original height of the specimen.
While the nominal stress was defined as s = F/(B × t₂),
where B and t₂ (not shown) are the width and out-of-
plane thickness of the compressed specimen. The
instantaneous time, displacement, force and Young’s
modulus of the compressed specimens were automati-
cally recorded by the computer connected to the
machine.
Figure 4. (a) A CAD model of a tensile sample (ASTM D638); (b)
quasi–static true stress–strain curves of the parent material HP
PA12 of four tensile samples manufactured by Multi Jet Fusion 3. Finite element analysis (FEA)
(MJF).
Finite element (FE) models were developed using
ABAQUS/Explicit package to simulate the behaviour of
(FE) models to describe material behaviour of PA 12. the specimens under quasi–static compression. It is
strue = sengineering × (1 + 1engineering ) (1) very time–consuming to numerically simulate a case
with a loading velocity of 0.066 mm/s. Therefore, a
1true = ln(1 + 1engineering ) (2) higher velocity, 100 mm/s, was used in the current simu-
where s and 1 are stress and strain, respectively. lation. Preliminary simulation indicated that the simu-
lation results were not sensitive to loading velocity
below 100 mm/s as shown in Figure 6(a). The dimensions
2.3.2. Quasi-static compressive tests of auxetic of the FE models were designed to be identical to those
structures of the experimental specimens listed in Table 1. Standard
The mechanical performance of auxetic specimens was shell elements (S4R) with four–node reduced integration
tested using a Zwick Roell machine (Zwick/Z010) were adopted. To determine proper element size and
equipped with a load cell of 10 kN. Figure 5 shows eliminate mesh sensitivity, four levels of element size:
the experimental setup of an anti–tetrachiral specimen. 0.5, 1, 2 and 4 mm, were employed to mesh the anti–tet-
To study the effect of loading direction on the mechan- rachiral honeycomb as an example. The stress–strain
ical performance, uniaxial quasi–static compressive tests curves are shown in Figure 6(b). The FE results of
were carried out in the two in–plane directions (X and Y) element sizes 0.5 and 1 mm were similar in the elastic
for the non–symmetric structures (RCA and re–entrant), regime and displayed a discrepancy of less than 10%
while in one in–plane direction for the symmetric struc- until 0.34 axial strain, demonstrating converged sol-
tures (tetrachiral and anti–tetrachiral). Two repeated utions. Therefore, the current FE models were estab-
tests were conducted under each loading condition. lished using element size of 1 mm. A strain hardening
The tests were performed by placing the specimen on material model was used and the true stress–strain
the fixed platen of the testing machine while a velocity curve (Test-1) shown in Figure 4 was input into
was applied to the top (movable) platen, which tra- ABAQUS/Explicit as material properties. A constant vel-
velled downward at a constant speed of 0.066 mm/s. ocity of 100 mm/s was assigned to the top (movable)
All tests were terminated once densification began. To platen, whilst all the translational and rotational free-
calculate the successive increments of the displace- doms of the bottom platen were constrained (i.e. fixed)
ments, a set of ten white markers were painted in the as shown in Figure 6 (c) and (d). To match with the

Table 2. Mechanical properties of HP PA12 material (average of four tensile tests).


Elastic properties
Young’s modulus Poisson’s Ratio (Habib et al. 0.2% offset yield strength Density (kg/
Test number (GPa) 2017) (MPa) m³)
Average 1.3 0.33 38 1000
Average plastic properties (stress versus plastic strain)
Plastic strain 0.00 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12
Plastic stress 38 40 44 48 51.6 52.8 55 55.8 56.2
(MPa)
6 A. ALOMARAH ET AL.

Figure 5. (a) A photograph of an anti–tetrachiral specimen before testing showing the ten markers which were used to determine the
axial and lateral displacements; (b) a photograph of the crushed anti–tetrachiral specimen.

experimental tests, ten markers were also selected in the estimated by a tilted plane test (Ma, Guo, and Lu 2012)
central region to calculate the axial and the lateral displa- and found to be 0.25, which was utilised in FE models.
cements. To avoid any possible penetration, a general It should be mentioned that the fracture was not con-
contact algorithm for ABAQUS/Explicit was defined to sidered in the current simulations.
simulate the interaction between walls of a specimen The validation of the current FE models was con-
as well as the contact between the specimen and the ducted by comparing the simulated deformation
top and bottom platens. Friction coefficient was modes, stress–strain curves and Poisson’s ratios with

Figure 6. (a) Comparison between the experimental and FE stress strain curves of anti–tetrachiral honeycomb using different velocities;
(b) mesh convergence test of FE model for anti–tetrachiral honeycomb using different elements sizes; (c) FE model of an anti–tetrachiral
honeycomb; (d) crushed FE specimen by moving the top platen toward the bottom (fixed) platen.
VIRTUAL AND PHYSICAL PROTOTYPING 7

the corresponding experimental results and shown later shown in Figure 7(b). Initially, the inclined walls (L₁)
in Sections 4.1 and 4.2. were subjected to bending while the (L₂) walls were sub-
jected to an axial loading. The compressive loading
caused an inward movement of the inclined walls (L₁)
4. Results and discussions leading to a lateral contraction of cells. This deformation
mode revealed a linear relation of the stress with the
4.1. Deformation modes and mechanical
strain up to ɛ = 0.04. Yield strain (1y ) was used to identify
responses
the end of the elastic regime at which the stress slope
4.1.1. Re–entrant chiral auxetic (RCA) structure started to decrease. The end of the plateau regime was
The experimental and the FE deformation mode and the identified by the intersection point of the tangents to
stress–strain curves of the RCA specimen compressed in the stress plateau regime and the densification regime
the X direction are depicted in Figure 7(a–c), respectively, (Chan and Xie 2003). The values of 1y and the end of
while Figure 7(d) shows a unit cell (non–deformed and the plateau regime for only the first specimen are
when the L₂ walls touched each other) allocated in the shown. Young’s modulus was recorded by the testing
central region of the FE model. Images were captured machine from the slope (the ratio of the stress over the
from the recorded videos during testing. It is clear that strain) in the limit 1% of nominal strain (Olurin, Fleck,
deformed specimen contracted laterally (resulting in and Ashby 2000). The recorded (experimental) and the
NPR) as illustrated by the measured displacements calculated (FE) values of Young’s modulus are listed in
between the markers as shown in Figure 7(a1-a3). FE Table 3. The lateral contraction of the deformed speci-
models revealed resemble deformation pattern as men continued until the (L₂) walls touched each other

Figure 7. Results of the RCA specimen compressed in the X direction: (a) photographs taken in the test; (b) simulated deformation; (c)
experimental measured and FE simulated stress–strain curves; (d) simulated unit cell located in the central region of the specimen (1-
non–deformed, δ = 0 mm; 2- when L₂ walls touched each other δ = 8 mm).
8 A. ALOMARAH ET AL.

(δ = 8) indicating the maximum lateral contraction toward the proximal layers. The sequential collapse of
(Figure 7(a3) and (b3)). At this point, the inclined walls the (H ) walls produced large fluctuated plateau stress.
(L₁) experienced severe bending. Therefore, the stress Finally, the stress increased sharply indicating the den-
decreased from 1 MPa (specimen–1) and 1.3 MPa (simu- sification. It is worth noting that the rotation of cylinders
lated) to 0.8 MPa (specimen–1) and 0.9 MPa (simulated). induced tension to the (L₂) walls, which experienced
Due to friction between the contacted surfaces, the great stress (Figure 8(d2)).
movement of cells at the distal ends of the specimen
were restricted and less than that of other cells leading
to in–plane buckling of the specimen. It can be seen 4.1.2. Re–entrant honeycomb
that localised layer collapse occurred in the middle of The experimentally measured and the FE simulated
the specimen (within the yellow rectangle shown in deformation mode and the stress–strain curves of the
Figure 7(a4)). All collapsed layers then touched each re–entrant specimen compressed in the X direction are
other, indicating the start of densification regime. From depicted in Figure 9(a–c), respectively, while a unit cell
Figure 7(d1), it can be seen that short arm of the before deformation and at a displacement of δ =
bending moment (ABM) of the inclined walls (L₁) required 5.12 mm (just before the in–plane buckling) located in
more force for further deformation. With further loading, the central region of the FE model is shown in Figure 9
the ABM of the inclined walls (L₁) increased (Figure 7(d2)) (d). The lateral contraction of the compressed specimen
(i.e. less force was required for further deformation). The came only from the inward movement of the inclined
effects of both the ABM and the in–plane buckling of the walls (L₁). Cells are deformed elastically and uniformly
specimen, led to softening (reduced plateau stress). as shown in Figure 9(a2). The stress of both experiment
Moreover, Figure 7(d) manifests the details of rotation and FE firstly increased linearly with strain in the elastic
of cylinders. Cylinders having chiral topology (cylinders regime and then increased nonlinearly and monolithi-
are on the opposite sides of a wall) rotated in the same cally from 0.65 MPa to approximately 1.8 MPa (exper-
direction. In contrast, cylinders having anti–chiral top- iments) and 2.15 MPa (FE) at the end of the plateau
ology (cylinders are on the same side of a wall) rotated regime. Both experimentally tested specimens displayed
in the opposite directions. The in–plane rotation of cylin- similar values of Young’s modulus while it was slightly
ders prompted additional lateral contraction of cells. smaller in the case of FE (Table 3). Subsequently, in–
Figure 8 is similar to Figure 7 except that the speci- plane buckling occurred early (Figure 9(a3)). The in–
mens were compressed in the Y direction. The com- plane buckling could be the main reason that caused a
pressed specimen contracted uniformly in both the discrepancy between plateau stresses (in the range
axial and lateral directions. At the beginning, the inclined 0.12–0.32 axial strain) of the experimental specimens.
walls (L₁) were subjected to bending while the (H ) walls With the progress of the deformation, the inclined
were subjected to axial loading. The end of the elastic walls (L₁) bent. A diagonal localised deformation band
regime was defined as the point in the stress–strain (within the orange rectangle shown in Figure 9(a4))
curve at which the slope or stress changed. From Table was observed. Such deformation pattern remained
3 it can be seen that the RCA structure displayed rela- until the whole specimen was fully compressed. From
tively small Young’s modulus when it compressed in Figure 9(d), it can be observed that the deformation of
the Y direction. The inferior elastic properties could be the (H ) walls was limited and stress concentration was
attributed to the long ABM shown in Figure 8(d1) com- present at the intersections where the inclined walls
pared with that in the case of X direction loading. After- joined other walls.
wards, when the (L₂) walls touched each other, the (H ) One has to bear in mind that the average compressive
walls are subjected to large axial force. The reduced strength (0.67 MPa) of the re–entrant specimens in the
length of the ABM (Figure 8(d2)) and the large axial plateau regime was smaller compared with that
force carried by (H ) walls led to a sharp increase of the (0.9 MPa) of the RCA specimens (X direction). This vari-
stress from 0.2 MPa (specimen–1 and simulated) at 0.18 ation could be due to two possible reasons. Firstly, in
axial strain to approximately 1.5 MPa at 0.26 axial the case of re–entrant specimens, there were no walls
strain. Because the (H ) walls were aligned in the aligned in the loading direction, while in the case of
loading direction, they yielded first and plastically RCA specimens the (L₂) walls were subjected to an axial
deformed leading to a significant decrease of the loading. Secondly, it has been observed in our previous
stress. Subsequently, the stress redistributed to the experiments (Alomarah et al. 2018b) that the effective
remaining walls in the same layer causing collapse of length of the inclined walls (L₁) of the re–entrant unit
all (H ) walls in the entire layer (within the yellow oval cell (hence the ABM) was longer than that of the RCA
shown in Figure 8(a4)). This deformation progressed (when they are designed to have similar dimensions).
VIRTUAL AND PHYSICAL PROTOTYPING 9

Figure 8. Results of the RCA specimen compressed in the Y direction: (a) photographs taken in the test; (b) simulated deformation; (c)
experimental measured and FE simulated stress–strain curves; (d) simulated unit cell located in the central region of the specimen (1-
non–deformed, δ = 0 mm; 2- when L₂ walls touched each other δ = 8 mm).

Figure 10 is similar to Figure 9 except that the speci- layer (within the orange oval shown in Figure 10(a4)).
men was compressed in the Y direction. The inclined Subsequently, the specimen deformed layer by layer,
walls (L₁) and the (H ) walls were subjected to both resulting in fluctuated stress in the plateau regime,
bending moment and axial compression simultaneously. until the whole layers touched each other indicating
Corresponding to the stress in the elastic regime, densification, which was similar to the deformation
Young’s modulus varied between the first and second mode of the RCA specimens (Y direction).
specimens (Table 3). With further loading, critical walls The fluctuation of plateau stress (Figure 10(c)) was
plastically buckled leading to collapse of the entire much smaller than that observed in the RCA specimens

Table 3. Young’s modulus (E) of the compressed specimens (Notes: letters S-1 and S-2 denote specimens No 1 and 2 respectively; X, and
Y are the loading directions).
Structure
Young’s modulus Type of test RCA-X RCA-Y Re-entrant -X Re-entrant -Y Tetra. Anti-tetra.
E (MPa) S-1 9.2 1.1 9.7 7.6 22 8.6
S-2 9.5 1.7 9.7 6.5 20 9.3
FEA 8 1.05 8 7.6 21 8.3
10 A. ALOMARAH ET AL.

Figure 9. Results of the re–entrant specimen compressed in the X direction: (a) photographs taken in the test; (b) simulated defor-
mation; (c) experimental measured and FE simulated stress–strain curves; (d) simulated unit cell located in the central region of the
specimen (1-non–deformed, δ = 0 mm; 2- at 0.08 axial strain, δ = 5.12 mm).

compressed in the Y direction (Figure 8(c)). The number respectively. While Figure 11(d) shows the FE model of
of the (H ) walls in a unit cell is the main reason for this a unit cell (un–deformed and at δ = 4 mm). Walls
variation. In the case of the RCA unit cell, the number almost aligned in the loading direction are subjected
of the (H ) walls (four) is double that of re–entrant unit to axial compressive loading and bent (due to the
cell. Therefore, the RCA specimen could withstand rotation of cylinders). The deformed specimen revealed
large axial loading before buckling (Figure 8(c)). From a small elastic regime with high strength. Therefore, tet-
the FE photographs shown in Figure 10(d2), it is clear rachiral honeycomb showed the largest values of
that the stress in inclined walls is large (at a certain Young’s modulus as listed in Table 3. When a critical
strain, ɛ = 0.08). stress in the walls aligned in the loading direction was
reached, cells started to deform plastically. Figure 11(a)
4.1.3. Chiral and anti-chiral honeycombs shows the plastic bending of the walls in the bottom
The chiral and anti-chiral specimens were loaded in only layer. Subsequently, the specimen deformed layer by
one direction due to their symmetric topology (i.e. the layer (within the orange rectangle shown in Figure 11
properties will be the same in both in-plane directions). (a2)). When a certain layer started to deform (Figure 11
The experimental measured and the FE simulated defor- (a) and (b)), the force started to increase (Figure 11(c)).
mation modes and the stress–strain curves of the tetra- The subsequent deformation localised in this layer and
chiral specimen are depicted in Figure 11(a–c), the deformation in other layers was not evident. Only
VIRTUAL AND PHYSICAL PROTOTYPING 11

Figure 10. Results of the re–entrant specimen compressed in the Y direction: (a) photographs taken in the test; (b) simulated defor-
mation; (c) experimental measured and FE simulated stress–strain curves; (d) simulated unit cell located in the central region of the
specimen (1-non–deformed, δ = 0 mm; 2- at 0.08 axial strain, δ = 5.12 mm).

when this deformed layer was completely crushed, the plane rotation of cylinders which rotated in the same
neighbouring layer started to deform and the force direction (Figure 11(d2)) and resulted in a full–wave or
started to drop. The layer by layer crushing resulted in S–shaped deformation of walls.
oscillation in the stress–strain curve. The crushing of The deformation pattern of the anti–tetrachiral speci-
one layer of cells corresponds to one period (trough – men and the corresponding stress– strain curves are
peak – trough) of the stress–strain curve (Figure 11(c)). shown in Figure 12(a) and (b), respectively. In the
A small lateral contraction was observed as illustrated elastic regime, the compressed specimens revealed
by the measured dimensions in Figure 11(a). This defor- different values of Young’s modulus. The movement of
mation pattern continued until all layers completely the cells at the distal ends was restricted due to friction
crushed forming densification. It should be noticed that and was less than that in the middle of the specimen
after the elastic regime, the experimental deformation (within the orange rectangle shown in Figure 12(a4)). A
of each layer produced almost identical stress slope to sudden decrease of the stress (specimen–1) was
that in the case of the elastic regime. However, the FE observed at 0.43 axial strain, which might be due to frac-
stress in the plateau regime was not resemble but the ture of some walls aligned in the loading direction.
average value was in good agreement with that of the Reviewing a unit cell in the FE model, it can be seen
experiments. The compressive load induced an in– that the adjacent cylinders were rotating in the opposite
12 A. ALOMARAH ET AL.

Figure 11. Results of the compressed tetrachiral specimen: (a) photographs taken in the tests; (b) simulated deformation; (c) exper-
imental measured and FE simulated stress–strain curves; (d) simulated unit cell (1-non–deformed, δ = 0 mm; (2) at 0.062 axial
strain, δ = 4 mm).

directions leading to a half–wave or C–shaped defor- the Poisson’s ratio of the RCA structure was measured
mation of walls (Figure 12(d2)). This caused the auxetic and compared with that of the other auxetic honey-
property of the compressed specimens. Moreover, combs. The deformation of specimens in all compressive
walls aligned in the loading direction were simul- tests were captured and recorded using a digital canon
taneously subjected to a relatively large axial compres- camera (Canon EOS 650D). A series of images (frames)
sive load and bending (coming from the rotation of of a deformed specimen were then captured. The instan-
cylinders), while walls aligned perpendicularly to the taneous change in the axial and lateral displacements of
loading direction were subjected to bending moment the traced markers was calculated using Matlab software.
predominantly. The average displacement between the top and the
bottom rows of the markers was taken as an axial displa-
cement. While the average displacement between the
4.2. Poisson’s ratio left and the right rows of the markers was taken as a
4.2.1. Calculation method lateral displacement. The true axial and lateral strains
Poisson’s ratio is an important material property, which is were calculated accordingly in which at each image (i),
the negative of the ratio of the lateral strain to the axial the preceded image (i-1) was used as a reference. Pois-
strain. The history of Poisson’s ratio of the tested speci- son’s ratio was calculated using Equation (3). Poisson’s
mens is one of the main interests of this study. Therefore, ratios were calculated up to 0.125 axial strain for all the
VIRTUAL AND PHYSICAL PROTOTYPING 13

Figure 12. Results of the compressed anti–tetrachiral specimen: (a) photographs taken in the test; (b) simulated deformation; (c) exper-
imental measured and FE simulated stress–strain curves; (d) simulated unit cell (1-non–deformed, δ = 0 mm; (2) at 0.062 axial strain,
δ=4 mm).

deformed specimens except for re-entrant honeycomb from rotation of the cylinders and in ward movements of
loaded in the X direction due to an in–plane buckling the inclined walls (L₁). When the RCA specimens were
shown in Figure 9. It is very challenging to trace the compressed in the X direction, they exhibited large nega-
markers after buckling. Therefore, the Poisson’s ratio tive Poisson’s ratio: −2.4 (experimental) and −2.6 (simu-
beyond buckling was not calculated. lated) at the beginning and then increased gradually to
1 true lateral approximately −2. Afterward, Poisson’s ratio increased
yxy = − (3) sharply to approximately −0.6 at 10% axial strain. This
1 true axial
behaviour agreed with the deformation mode observed
where yxy and 1 are Poisson’s ratio and strain, in Figure 7(a) and (b) in which the lateral contraction of
respectively. the compressed specimens was significantly restricted
when the (L₂) walls touched each other. Subsequently,
4.2.2. Poisson’s ratios of the tested specimens Poisson’s ratio continued to increase, but at a much
Figure 13 shows the experimental and simulated Pois- smaller rate. Poisson’s ratio remained negative in the
son’s ratios versus the axial engineering strain. Poisson’s whole compressive process. On the other hand, for the
ratios of the RCA specimens compressed in the X and Y RCA specimens compressed in the Y direction, the Pois-
directions are shown in Figure 13(a) and (b), respectively. son’s ratio was relatively small and remained constant
The auxetic property (i.e. NPR) of the RCA structure came approximately −1.1.
14 A. ALOMARAH ET AL.

Figure 13. Experimental and FE Poisson’s ratios of (a) RCA structure compressed in the X direction; (b) RCA structure compressed in the
Y direction; (c) re–entrant honeycomb compressed in the X direction; (d) re–entrant honeycomb compressed in the Y direction; (e)
tetrachiral honeycomb; (f) anti–tetrachiral honeycomb.

Figure 13 (c) and (d) show the Poisson’s ratios of re– in the Y direction, Poisson’s ratios were −1 at the begin-
entrant honeycomb specimens when they were com- ning and increased gradually with the axial strain to
pressed in the X and Y directions, respectively. It is approximately −0.7 (Figure 13(d)).
known that the re-entrant honeycomb displays large Figure 13(e) and (f) show the Poisson’s ratios of the tet-
auxetic effect (i.e. large NPR) when it is compressed in rachiral and anti–tetrachiral honeycombs respectively. The
the Y direction (Yang et al. 2015). As stated in Section auxetic feature of the chiral honeycombs came from
4.1.2, the lateral contraction of the re–entrant honey- rotation of cylinders. It was previously reported that the
comb came only from the inward movement of the theoretical Poisson’s ratio of chiral honeycombs is −1
inclined walls (L₁). Therefore, Poisson’s ratios were (Prall and Lakes 1997). The Poisson’s ratio of the current
expected to be smaller compared with those for the anti-tetrachiral honeycomb was −1, the same as the theor-
RCA specimens. In the case of compression in the X direc- etical prediction. However, the current tetrachiral honey-
tion, the experimental and simulated Poisson’s ratios comb displayed a slightly different value of Poisson’s
were approximately −0.7 at the beginning then it ratio of approximately −0.8 (experimental) and −0.76
decreased gradually with the axial strain to approxi- (simulated). This could be due to the relatively small
mately −0.8 (Figure 13(c)). In the case of compression lateral deformation illustrated in Section 4.1.3. It is worth
VIRTUAL AND PHYSICAL PROTOTYPING 15

noting that the theoretical results mentioned above did For clarification, the calculated values of the 1cd and
not consider the axial and shear deformation of the walls the absorbed energy (shaded area) of one experimental
or any deformation of the cylinders (Bornengo, Scarpa, RCA specimen when it was loaded in the X and Y direc-
and Remillat 2005). A discrepancy between the experimen- tions are shown in Figure 14(a) and (b), respectively.
tal and FE Poisson’s ratio of the chiral honeycombs has From Figure 14, it is noted that most of the energy was
been noticed due to a kink in the data of the experimental absorbed in the plateau regime. Therefore, the magni-
lateral strain (Alderson et al. 2010). tude of plateau stress (s pl ) and its length are encoura-
ging to guarantee a sufficient energy absorption (Habib
et al. 2017). The plateau stress of the compressed speci-
4.3. Energy absorption mens was calculated using Equation (6) (Li, Magkiriadis,
Energy absorption capacity of structure is an important and Harrigan 2006).
indicator for their applications. From an energy absorp- 1cd
1y s(1)d1
tion prospective, relative density is an important par- s pl = (6)
1cd − 1y
ameter (Avalle, Belingardi, and Montanini 2001). The
absorbed energy per unit mass SEA (specific energy where 1y is the yield strain. The calculated values of the
absorption) and per unit volume Wv were also important 1cd and s pl are summarised in Table 4. It is clear that the
indicators in evaluating the energy absorption capacity. re–entrant honeycomb showed the smallest 1cd (i.e. they
The absorbed energy of the tested specimens was calcu- densified earlier than the RCA, chiral and the anti-chiral
lated up to the onset of densification strain (1cd ) The 1cd specimens).
is the strain where densification initiates (Li, Magkiriadis, The absorbed energy per unit volume, Wv , was calculated
and Harrigan 2006). Several methods were proposed to as the cumulative areas under the stress–strain curves up to
determine the 1cd (Chan and Xie 2003; Vural and Ravi- the onset of densification strain (1cd ) using Equation (7),
chandran 2003; Onck, Andrews, and Gibson 2001). In while the SEA was calculated using Equation (8).
the current study, energy efficiency method was used 1cd
(Shen, Lu, and Ruan 2010; Onck, Andrews, and Gibson Wv = s(1)d1 (7)
2001). Based on this method, the energy absorption 0

efficiency, E, is calculated as the area under a stress– SEA = Wv /r (8)


strain curve divided by the instantaneous stress (sa ):
1a
where s is the stress and r is the density of a structure.
s(1)d1 Figure 15(a) and (b) show the calculated values of the
E(1a ) = 0
, 0 ≤ 1a ≤ 1 (4)
sa Wv and SEA of the four auxetic structures. It can be
where 1a is the strain at sa . Energy efficiency was plotted seen that the energy absorption capacity of the RCA
versus nominal engineering strain and 1cd was defined as structure was remarkably dependent on the loading
the value of the strain that corresponds to the maximum direction. In the case of compression in the Y direction,
efficiency: the RCA structure revealed the highest specific energy
absorption (SEA and Wv ) than other auxetic honey-
dEa (1a )
| = 0 0 ≤ 1cd ≤ (5) combs. However, in the case of compression in the X
d1 1a =1cd
direction, the specific energy absorption of the RCA

Figure 14. Stress-stain curves and energy efficiency curves of one experimental specimen of the RCA structure compressed in the: (a) X
direction; (b) Y direction.
16 A. ALOMARAH ET AL.

Table 4. Onset strain of densification (1cd ), and plateau stress of the compressed specimens (Notes: letters S-1 and S-2 denote
specimens No 1 and 2 respectively; X and Y are the loading directions).
RCA-X RCA-Y Re-entrant -X Re-entrant -Y Tetra. Anti-tetra.
Calculated parameters S-1 FEA S-1 FEA S-1 FEA S-1 FEA S-1 FEA S-1 FEA
1cd 0.43 0.45 0.53 0.56 0.32 0.35 0.34 0.40 0.64 0.62 0.44 0.48
spl (MPa) 0.89 0.91 1.35 1.60 0.64 0.67 0.47 0.50 0.59 0.74 0.59 0.79

structure was smaller than that of the tetrachiral honey- were employed. The FE models were the same as
comb, while it was higher than that of all other honey- those described in Section 3 except the values of fric-
combs. Note that the re–entrant honeycomb showed tion coefficient (μ). Five cases with various friction
the smallest SEA and Wv . coefficients, μ = 0, μ = 0.25, μ = 0.5, μ = 0.75 and μ =
1, were considered. Figure 16(a–b) shows the FE
models (non–deformed and at 0.15 axial strain
5. Effect of friction when μ = 1), the lateral global dimension of the orig-
In order to investigate the effect of friction on the inal specimen is represented by the red dashed lines.
FEA results, the validated FE models of RCA structure Figure 16(c–d) shows the stress–strain curves of the

Figure 15. Energy absorption capacity of the four auxetic structures up to the onset strain of densification 1cd : (a) specific energy
absorption per unit volume (Wv ); (b) specific energy absorption per unit mass (SEA).
VIRTUAL AND PHYSICAL PROTOTYPING 17

Figure 16. (a) FE photographs of the compressed RCA specimens (1- non deformed; 2- at 0.15 axial strain when μ=1) and the effect of
friction on the stress–strain curves; (a) and (b) compression in the X direction; (c) and (d) compression in the Y direction. Dashed lines
represent the lateral global dimension of the original specimen.

RCA structure when different values of μ were effect of number of unit cells of RCA structures,
employed. Results showed that the larger the friction numerical simulation was conducted. The settings of
coefficient, the larger the stress level. For both the FE models such as element size, material proper-
loading directions, when the friction was large (μ ≥ ties, friction coefficient, boundary and loading con-
0.75), the stress-strain curves were almost the same. ditions were taken as the same as those described in
However, the effect of friction on the RCA com- Section 3. Due to the non–symmetricity of the RCA
pressed in the X direction was more evident com- unit cell in the X and Y directions, the number of FE
pared with that in the case of compression in the Y models varied corresponding to the loading direction
direction. This is due to the different deformation to prevent buckling. Seven FE models were developed
modes of the RCA specimens under compression in in the case of X direction compression (Figure 17(a)): 2
the different directions as mentioned in Section × 1 (=2), 3 × 2 ( = 6), 4 × 2 ( = 8), 5 × 3 ( = 15), 6 × 3 ( =
4.1.1. Moreover, when the RCA is compressed in the 18), 7 × 4 (=28) and 8 × 4 ( = 32) cells, while five FE
Y direction and the interaction between the speci- models were developed in the case of Y direction
mens and the compressive platens (top and compression (Figure 17(b)): 2 × 1 (=2), 3 × 2 ( = 6), 4
bottom) was frictionless (μ = 0), the stress–stain × 3 ( = 12), 5 × 4 ( = 20) and 6 × 5 ( = 30) cells. The
curve is considerably different from those when fric- stresses were plotted as a function of number of
tion exists. unit cells as shown in Figure 17(c). It can be seen
that when the number of cells < 15, the stress was sig-
nificantly affected, while when the number of cells ≥
6. Size effect of RCA specimens
15, the stress plateaued out. These results confirmed
Previous studies manifested that the number of cells that the number of cells of the experimental speci-
has a significant effect on the mechanical properties mens used in this study was reasonable, in which
of cellular structures (Yang et al. 2015; Onck, the bulk properties of the RCA structure were
Andrews, and Gibson 2001). In order to evaluate the obtained.
18 A. ALOMARAH ET AL.

Figure 17. Size effect on the mechanical response of the RCA structure: (a) FE models of the compression in the X direction (numbers
under each model are the numbers of unit cell); (b) FE models of the compression in the Y direction; (c) stress vs. number of unit cells.

7. Concluding remarks 2. The mechanical performance of the non–symmetric


structures varied based on the alignment of cells cor-
In this study, the compressive properties of re–entrant
responding to the applied load. In the case of RCA
chiral auxetic (RCA) and three popular honeycombs
structure, the mechanical performance was sensitive
(re–entrant, tetrachiral and anti– tetrachiral) were
to the load direction (anisotropic response).
examined. Multi Jet Fusion (MJF) 3D printing tech-
3. The RCA structure exhibited larger stress than other
nique was used to manufacture twelve specimens
auxetic honeycombs. However, the RCA structure
from polyamide 12 (PA12). The in–plane deformation
revealed low elastic stress when it was loaded in the
modes, stress–strain curves, energy absorption and
Y direction.
auxetic behaviour of the tested specimens were inves-
4. The lateral contraction came mainly from the inward
tigated. Friction and size effects were numerically
movement of the inclined walls and rotation of cylin-
examined. The main concluding remarks are drawn
ders in the case of the re–entrant honeycomb and
as follows.
chiral honeycombs, respectively. Since the unit cell
of the RCA structure combines the topological fea-
1. A successful fabrication of the printed specimens with tures of both honeycombs, the lateral contraction
high-precision dimensions has been achieved using came from both factors. In the Y direction, the
Multi Jet Fusion (MJF). auxetic feature (i.e. negative Poisson’s ratio) of the
VIRTUAL AND PHYSICAL PROTOTYPING 19

RCA structure was consistently larger than that of the Syed H. Masood is Full Professor in the Department of Mechan-
other honeycombs, whereas in the X direction, the ical and Product Design Engineering at Swinburne University of
Technology, Melbourne, Australia. His research interests are
auxetic feature of the RCA structure was much
mainly focused on Advanced Manufacturing Processes, Addi-
larger than that of other honeycombs up to a strain tive Manufacturing, Fused Deposition Modelling, Selective
of 0.08. Laser Melting, Direct Metal Deposition, Cold Spray and Rapid
5. The RCA structure compressed in the Y direction dis- Tooling. He has published over 360 articles in international jour-
played the highest specific energy absorption (SEA nals and conferences to date, and has received several major
and Wv ) among all other auxetic honeycombs research grants in these areas.
studied in this paper, while the specific energy Igor Sbarski is an Associate Professor in the Department of
absorption of only the tetrachiral honeycomb Mechanical and Product Design Engineering, Faculty of
Science, Engineering and Technology at Swinburne University
surpass that of the RCA structure compressed in the
of Technology, Australia. His research interests include Poly-
X direction. mers, Plastics and Mechanical Engineering.
6. The FE simulation revealed that the effect of friction
Batool Faisal is an Associate professor in the Department of
was more evident when the RCA structure is sub- Mechanical engineering, Faculty of Engineering at Wasit Uni-
jected to compression in the X direction loading versity, Iraq. Her researches focus on viscoelastic behaviour of
than that in the Y direction. In both loading directions, engineering materials, nanotechnology and their applications
friction effect was significantly decreased when fric- especially in biomechanical field.
tion coefficient was large (μ ≥ 0.75). Zhanyuan Gao is a lecturer in the School of Civil Engineering,
7. The FE results confirmed that the number of unit cells TianJin ChengJian University, China. His research interests
include dynamic analysis of structures.
of the experimental specimens of the RCA structure
used in this study was reasonable and achieved the Dong Ruan is Full Professor in the Department of Mechanical
and Product Design Engineering at Swinburne University of
bulk properties.
Technology, Australia. Her research interests include character-
8. This study indicates that the RCA structure is a prom- isation of the mechanical properties of various materials at high
ising energy absorber under quasi-static uniaxial strain rates, evaluation of the mechanical response of structures
loading. In engineering applications, structures may subject to dynamic loading, and additive manufacturing.
be subjected to loading in more than one direction
as well as dynamic loading. Therefore, future work is
expected to examine the in-plane mechanical proper- ORCID
ties of the RCA structure under biaxial compression Amer Alomarah http://orcid.org/0000-0001-5783-1292
and dynamic loading. Dong Ruan http://orcid.org/0000-0001-8463-0568

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