Simulation of fused deposition modeling of glass fiber reinforced ABS impact samples: The effect of fiber ratio, infill rate, and infill pattern on warpage and residual stresses

Abstract

It is known that products made of polymer materials or especially polymer materials with glass fiber and carbon fiber are used in many different areas such as automotive, aerospace, and defense. At this point, studies in the literature have gained momentum due to the combination of fiber-reinforced polymer materials emerging as a result of technological developments and industrial demands, and the fused deposition modeling (FDM) method providing the production of parts in desired sizes and complexity. Residual stresses and distortions occurring in polymer-based composite parts produced with FDM are among the problems that should be minimized. In this study, the influences of fiber ratio (%10, %15, and %20), infill rate (%20, %50, and %80), and infill pattern (line, honeycomb, and triangle) on the residual stresses and warpages generating in impact test specimens produced from glass fiber reinforced ABS filaments by fused deposition modeling were tried to be determined with the Digimat 2021 program. As a result of the findings, it was determined that the distortion values decreased and the thermal residual stress values went up with the increase in fiber ratio and infill rate. In addition, it can be reported that the distortions that bring out as a result of the separation of the produced parts from the production platform are caused by the high deformations condensing at the lower corner points of the parts.