Investigation of Composite Mechanical Properties from Additive Manufacturing

Abstract

Manufacturers consider carbon fiber as a wonder material for the world's economy. Its distinctive combination of high strength and low weight has helped drive the wind power revolution and make aircraft and ships more fuel-efficient. In addition, the carbon fiber structures can function longer and are more rigid than the traditional metallic models, making them more resilient in cold and more efficient in corrosive environments. Automobile makers also realize the material's potential to make lighter and more efficient vehicles. But, despite all the benefits of carbon fiber, there is a key problem associated with it; the high-technology material is wasteful to produce and very difficult to recycle. As carbon fiber (prepreg) is combined with a plastic polymer resin in a fixed ratio to manufacture the strong, light composite material, often the manufacturing process, in which sheets of composite material are laid up, produces tons of waste. By the time they have been trimmed to the required size, almost a third of these carbon fiber sheets end up as waste on factory floors. This research proposal explores 3D printing as an alternative to conventional manufacturing processes. 3D printing is an additive manufacturing process in which layers of material are built-up to yield accurate parts with a nearly flawless surface finish, saving almost one-third of the material waste from conventional manufacturing methods. However, the industrial benefits of composite 3D printing technology are still limited owing to the lack of knowledge regarding the performance of 3D printed parts during their intended applications.This presentation intends to discuss the mechanical properties of CFRP by performing standard mechanical tests i.e., tensile, Charpy, penetration resistance, drop-weight, and fatigue, and also validates them through numerical analysis. Furthermore, this presentation will take Numerical Modeling and Simulation to a new level by aiming to solve the problem of interfacial gaps between 3D printed layers and infill patterns that do not conform with conventional continuum-based Finite Element Method (FEM) material models. New findings in FEA will help the scientific community to handle similar problems. The success of 3D printing composite parts with the required mechanical properties will revolutionize the composite manufacturing industry and help in reducing carbon footprint and achieving environmental sustainability.