Additive Manufacturing (AM) has become a widely used industrial process, allowing fast, flexible and economical production of small and medium size batches of complex parts. In particular, parts manufactured with high-performance grade materials such as PEKK (Polyetherketoneketone) and PEI (Polyethyleneimine) are already used in the aerospace, defense and transportation industries. The current use of these additively manufactured parts is wide, but however hindered by the lack of design validation methods that prevent engineers from analyzing the mechanical performance of these printed parts when structurally loaded. Therefore, a methodology is required that takes into account the anisotropy of the mechanical properties that are depending on the material and process parameters in order to simulate the printed part performance. The methodology is developed in the framework of the CALFDM project, a Walloon Region (Belgium) funded collaborative research project. Firstly, it consists of the experimental characterization of a PEKK material (ULTEM 9085). A testing campaign is performed in order to address different printing configurations, load cases and geometries with a progressive increase of complexity from coupon to component level. Secondly, the corresponding anisotropic material model is calibrated to reproduce the mechanical responses of specimen printed using different printing parameters. Finally, the material card is applied at component level, a bellcrank used to control the roll of an aerobatic airplane. A finite element analysis (FEA) model of the bellcrank component is created where aerodynamic loads are applied on the bellcranck. A strong coupling between the additive manufacturing process and structure is ensured by the usage of the anisotropic material model, which is itself dependent on the process parameters, such as the toolpath. Accurate predictions of the stiffness and strengths and failure area as a function of the toolpath strategy are obtained in the framework of this study.
Reference | NWC23-0390-extendedabstract |
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Authors | Lavertu. P-Y Lietaer. O |
Language | English |
Type | Extended Abstract |
Date | 16th May 2023 |
Organisation | Hexagon |
Region | Global |
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