Multiphysics Simulation of Additive Manufacturing-Induced Fracture Mechanics using Peridynamic Theory

Presentation link

Jan-Timo HesseORCID Symbol, Christian WillbergORCID Symbol, Felix Winkelmann, Robert HeinORCID Symbol

18th International Conference on Computational Plasticity - COMPLAS 2025
2-5 September, 2025 - Barcelona

Presentation URL: https://perihub.github.io/Presentations/COMPLAS_2025
Questions

Introduction 3D printing

- Additive extrusion processes enables manufacturing of complex structures without moulds

  • Many process parameters influence the final properties

    • Individual process parameter - property relation often unclear

  • Process simulations can help to predict the properties and evaluate the process parameters

Questions

Introduction polymer crystallization

- Crystallization influences the mechanical and technical properties of the material

  • Degree of crystallization depends on material properties and cooling conditions

  • Complex processes during cooling in deposition processes

Figure Source: Yang et al., Influence of thermal processing conditions in 3D printing ...
Questions

Subroutine

  • Calculation of crystallization based on dual kinetic model (by Velisaris Seferis ggf. Tonspur)

  • Implementation in Fortran Subroutine for usage in Abaqus

    • Calculates crystallization kinetics through process simulation
    • Degree of crystallization at every time step

  • Temperature and time from the process simualtion are inputs for the subroutine

Figure Source: Yang et al., Influence of thermal processing conditions in 3D printing ...
Questions

Experiment

Figure Source: Yang et al., Influence of thermal processing conditions in 3D printing ...
Questions

Dogbone Specimen

Specimen Geometry: ASTM E647-15
Questions

Experimental Setup

Material: PEEK (Polyetheretherketon)

Parameter Value

Thermal Properties

Parameter Value

Questions

Experimental Results

Questions

Experimental Results


Questions

Dogbone Specimen | PeriLab Results

Questions

Load-Displacement

Questions

Discussion and further work

  • Lorum

Questions

Thank you

Jan-Timo Hesse (DLR)
Christian Willberg (h2)
Felix Winkelmann (DLR)
Robert Hein (DLR)

References

  1. J. Shah, B. Snider, T. Clarke, S. Kozutsky, M. Lacki & A. Hosseini (2019). Large-scale 3D printers for additive manufacturing: design considerations and challenges.
  2. C. Yang, X. Tian, D. Li, Y. Cao, F. Zhao & C. Shi (2017). Influence of thermal processing conditions in 3D printing on the crystallinity and mechanical properties of PEEK material.
  3. C. Willberg, J-T. Hesse, R. Hein & F. Winkelmann (2024). Peridynamic Framework to Model Additive Manufacturing Processes.
  4. C. Willberg, J-T. Hesse & A. Pernatii (2024). PeriLab - Peridynamic Laboratory.

Funding

Name Logo Grant number
German Research Foundation WI 4835/5-1
Saxon State Parliament 3028223
Federal Ministry for Economic Affairs and Climate Action 20W2214G

-We could determine three diferent failure mechanisms by looking at the crack surface