Determination of initial failure loads of 3D printed ABS polymers reinforced with different Kevlar/epoxy composite layers using the finite element method

Year 2025, Volume: 5 Issue: 2, 507 - 519, 31.07.2025

Semih Benli

https://doi.org/10.61112/jiens.1602722

Abstract

Additive manufacturing (AM) is a manufacturing method that is rapidly advancing in industrial applications and is also known as 3D printing. Fused Deposition Modeling (FDM) is one of the widely used additive manufacturing techniques due to its ability to produce complex and relatively high strength parts from low-cost polymer materials. One of the most widely used materials with FDM is acrylonitrile butadiene styrene (ABS). However, the low strength and elastic modulus of ABS limit its use alone. The aim of this study was to determine the failure load of different sandwich structures formed with knitted Kevlar/epoxy composite layers in order to improve the properties of ABS by using the finite element method in the ANSYS program. For this purpose, finite element models of tensile and bending samples reinforced by gluing single and double-layered, 0° and 45° oriented Kevlar/epoxy composite layers to the upper and lower surfaces of ABS with FM73 epoxy adhesive were created. For the simulation of tensile and three-point bending tests, the properties of the materials were entered into the program separately, and loading and boundary conditions were applied. In order to determine the initial damage load, the Tsai-Wu strength index value was examined and the damage loads that made this value 1 were determined. Accordingly, although the woven Kevlar/epoxy composite layers carried most of the load during tensile and bending, the initial damage occurred in the ABS layers. As a result, it was observed that the reinforcement of ABS with woven Kevlar/epoxy composite layers significantly increased both rigidity and strength.

Keywords

Kevlar/epoxy composite layer , Finite element method , Tsai-Wu strength index , Initial damage load

Farklı Kevlar/epoksi kompozit tabakalarla takviye edilmiş 3D baskı ABS polimerlerin sonlu elemanlar yöntemi ile ilk hasar yüklerinin bulunması

Abstract

Eklemeli imalat (Additive manufacturing, AM), endüstriyel uygulamalarda hızla ilerleyen ve 3 boyutlu (3D) baskı olarak da bilinen bir imalat yöntemidir. Eriyik yığma modelleme (Fused Deposition Modeling, FDM), düşük maliyetli polimer malzemelerden karmaşık ve nispeten yüksek mukavemetli parçalar üretme kabiliyeti nedeniyle yaygın olarak kullanılan eklemeli imalat tekniklerinden biridir. FDM ile en yaygın kullanılan malzemelerden biri akrilonitril bütadien stiren (ABS) dir. Ancak, ABS'nin düşük dayanım ve elastik modülüne sahip olması tek başına kullanımını sınırlandırmaktadır. Bu çalışmanın amacı, ABS’nin özelliklerini iyileştirmek amacıyla örülmüş Kevlar/epoksi kompozit tabakası ile oluşturulan farklı sandviç yapıların hasar yükünü ANSYS programında sonlu elemanlar yöntemi kullanarak belirlemektir. Bu amaçla, ABS’nin alt ve üst yüzeylerine tek ve çift katmanlı, 0° ve 45° oryantasyonlu örülmüş Kevlar/epoksi kompozit tabakaları FM73 epoksi yapıştırıcı ile yapıştırılarak takviye edilmiş çekme ve eğme numunelerinin sonlu elemanlar modelleri oluşturulmuştur. Çekme ve üç nokta eğme testinin simülasyonu için malzemelerin özellikleri ayrı ayrı programa girilmiş, yükleme ve sınır koşulları uygulanmıştır. İlk hasar yükünü belirlemek için Tsai-Wu dayanım indeks değerine bakılmış ve bu değeri 1 yapan hasar yükleri tespit edilmiştir. Buna göre, çekme ve eğme esnasında yükün büyük kısmını örülmüş Kevlar/epoksi kompozit tabakalar karşılamasına rağmen ilk hasar ABS tabakalarında meydana gelmiştir. Sonuç olarak, ABS’nin örülmüş Kevlar/epoksi kompozit tabakalarla takviyesinin hem rijitliği hem de mukavemeti önemli ölçüde arttırdığı görülmüştür.

Keywords

Kevlar/epoksi kompozit tabaka , Sonlu elemanlar metodu , Tsai-Wu dayanım indeksi , İlk hasar yükü

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