Numerical modelling on polymer composites prepared via large area extrusion-deposition additive manufacturing: fibre orientation, material inhomogeneity, and thermal-mechanical responses during material loading process

ABSTRACT The flow-induced fibre orientation formed during polymer extrusions causes the composite to exhibit non-homogeneous thermal-mechanical behaviours during Large Area extrusion-deposition Additive Manufacturing (LAAM) processes. This study numerically evaluates the fibre orientation state of a 20 wt.% short carbon fibre reinforced polyethylenimine fabricated by LAAM. The fibre orientation state of the solidified deposited bead is determined by a fully coupled flow/orientation simulation approach. The material properties of deposited composites are computed by assuming that the deposited bead has heterogeneous regions with varying local fibre orientation states. A finite element simulation is performed to model the LAAM process of a thin-wall structure, where the predicted inhomogeneous material properties are employed. Computed results show notable differences between simulations performed by employing homogenous properties and those obtained using heterogeneous properties. The bead-direction tensile stress contours computed under the heterogeneous assumption are comparable to experimental data in the literature, supporting our numerical approach.