Abstract—Fused deposition modeling (FDM) for additive
manufacturing is constantly growing as an innovative process across the industry in areas of prototyping, tooling, and
production parts across most manufacturing industry verticals such as Aerospace, Automotive, Agricultural, Healthcare, etc.
One such application that is widely used is for tooling on the
shop floor e.g. for pick-off tools, assembly fixtures etc. For
tooling applications printing the solid fill component with +45/-
45 raster is common practice. There is a requirement for finite
element analysis to validate the strength of 3D printed
components for some specific applications in tooling, but due to
the anisotropic behavior of 3D printed parts and the
unavailability of all mechanical properties FE analysis of 3D
printed parts is sometimes challenging. Advance approaches
like multiscale modeling approach requires specialized & costly
analytical tools. So, to understand the behavior of additively
manufactured parts the team has conducted a few tests and
compared the results. In this work, solid-filled dog-bone tensile
test and three-point bending test specimens were printed with
+45/-45 raster orientation and tested in the lab. Tensile test
specimens were built with flat, on-edge, and up-right
orientations and tested to determine the directional properties
of young’s modulus. Using mechanical properties from the
tension test 3 points bending test is simulated in FE software-
ANSYS. The FE modeling was done in two ways, in first model
orthotropic properties were assigned to the specimen, and for
second model isotropic properties were assigned. For isotropic
modeling least value of young’s modulus is used. Simulation
results of three-point bending test shows that in the linear region
of force-deflection curve, deformation values from FE model
with both orthotropic and isotropic modeling are in good
agreement with the experimental results. Also, the difference in
stress results between isotropic and orthotropic FE model is
almost negligible. To support this observation, study is
performed for various conditions. The specimens were printed
with ABS material on Ultimaker® and ASA material on
Stratasys® Fortus 360mc™ machine with T12, T16 and T20
nozzle settings. Study shows, for tooling applications if the 3D
printed solid-filled components are designed with a certain
factor of safety then validating its strength with isotropic
material properties will give acceptable results. The advantage
of this approach is getting the isotropic mechanical properties is
easy and modeling with FE modeling will be simple.
Index Terms—3D-printing, additive manufacturing, mechanical properties of materials, Finite Element Analysis (FEA).
The authors are with John Deere India Pvt Ltd., India (email: WaradNilesh@johndeere.com, sammetajanardhanrao@johndeere.com, kulkarnikedar@johndeere.com, dandekaravinash@johndeere.com, salgarmanojkumar@johndeere.com, kulkarnimalharms@johndeere.com).
Cite: Nilesh Warad, Janardhan Rao, Kedar Kulkarni, Avinash Dandekar, Manoj Salgar, and Malhar Kulkarni, "Finite Element Analysis Methodology for Additive Manufactured Tooling Components," International Journal of Engineering and Technology vol. 14, no. 4, pp. 56-61, 2022.
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