Additive manufacturing and experimental study of topology optimized structures with improved fracture performance

Ahmed, Asad Farooq

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https://hdl.handle.net/2142/117603 Copy

Description

Title

Additive manufacturing and experimental study of topology optimized structures with improved fracture performance

Author(s)

Ahmed, Asad Farooq

Issue Date

2022-12-08

Director of Research (if dissertation) or Advisor (if thesis)

Zhang, Xiaojia Shelly

Department of Study

Civil & Environmental Eng

Discipline

Civil Engineering

Degree Granting Institution

University of Illinois at Urbana-Champaign

Degree Name

M.S.

Degree Level

Thesis

Keyword(s)

Fracture, Optimized Designs, Water washable resin, Standard photopolymer resin, Experimental testing, Numerical Analysis

Abstract

This thesis focuses on additive manufacturing and experimental validation of optimized structures for improved fracture responses. In this thesis, five optimized designs are investigated from both fabrication and experimental validation perspectives using two dissimilar materials. This thesis first aims at exploring suitable materials to manufacture the optimized designs. Additive manufacturing was employed to fabricate optimized structures because of its ability to handle complex geometries. Micro stereolithography compatible materials, elegoo standard photopolymer (SP) and water washable (WW) resins, were identified as suitable because of the inherent advantage of isotropic printing in stereolithography. Material characterization of selected materials was done to finalize the mechanical properties, which include tensile strength, compressive strength, young’s modulus, Poisson ratio, and critical strain energy release rate. These properties were then employed in the numerical simulations to obtain results corresponding to each type of materials. Employing the chosen materials, the optimized designs are manufactured and experimentally tested for their fracture behaviors using the three-point bending setup. Finally, the experimental results are compared and studied with the results obtained from numerical simulations. The investigations and observations from the fabrication and experimental study contribute to our understanding of the following four areas (1) material characterization and experimental testing for resin materials, (2) various types of additive manufacturing and processes involved in the studied resin materials, (3) experimental validation of topology optimized designs, and (4) material behavior and variations associated with the resin specimen. This body of work could provide a guideline for material characterization and experimental validation of optimized designs.

Graduation Semester

2022-12

Type of Resource

Thesis

Copyright and License Information

Copyright 2022 Asad Ahmed

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