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Thesis
Integrated design of 3D materials
Master of Science (M.S.), Drexel University
Jun 2018
DOI:
https://doi.org/10.17918/6r8w-qw96
Abstract
Advanced manufacturing (AM) refers to design and manufacturing through the combination of sensing, information, computation, software, testing, and/or the use of novel materials. Although several examples on the use of AM methods to design novel 3D-architectured materials have been proposed, a critical challenge in such approaches remains the validation of simulation results as well as manufacturing procedures especially in the context of the reported variability in both properties and behavior for current AM methods. An appropriate component to benchmark design for AM is their pairing with advanced testing and characterization methods capable to provide quality assessment either in situ or in post mortem. This thesis targets, therefore, the investigation of a proof-of-concept methodology that combines computational modeling with testing methods to attempt to close the loop between digital design and final manufactured product. To demonstrate such approach, Fused Deposition Modeling (FDM), an extrusion-based process in which molten filament is deposited and rapidly solidified on a heated build plate, constructing parts in a layerwise fashion is chosen due to its widespread use. For computations, an Interface-enriched Gradient-based Finite Element Method (IGFEM) shape optimization was utilized to select the optimal shape of a designed exemplary microstructure consisting of an elliptical hole. A specific criterion for optimization was used involving the overall compliance of the 3D-printed geometry which in this case was in the form of uniaxial tension test specimens. For experimental validation, FDM produced coupons using ABS were tested and compared against the simulated microstructure. Extensions of this study in the cases of more complex microstructures consisting of several volume fractions of different types of microstructures in similar specimens, as well as compression loading specimens are reported to demonstrate the way such method could reduce design time while being validated.
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Details
- Title
- Integrated design of 3D materials
- Creators
- Daniel Christe - DU
- Contributors
- Antonios Kontsos (Advisor) - Drexel University (1970-)Ahmad Raeisi Najafi (Advisor) - Drexel University (1970-)
- Awarding Institution
- Drexel University
- Degree Awarded
- Master of Science (M.S.)
- Publisher
- Drexel University; Philadelphia, Pennsylvania
- Number of pages
- viii, 56 pages
- Resource Type
- Thesis
- Language
- English
- Academic Unit
- College of Engineering (1970-2026); Mechanical Engineering (and Mechanics) [Historical]; Drexel University
- Other Identifier
- 8251; 991014632584104721