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Sciencedirect: Finite Element Analysis and Validation of Cellular Structures
Sciencedirect: Finite Element Analysis and Validation of Cellular Structures
Sciencedirect: Finite Element Analysis and Validation of Cellular Structures
com
ScienceDirect
Procedia CIRP 50 (2016) 94 – 99
∗ Corresponding author. Tel.: +61 (2)-9933-3666; fax: +61 (2)-9933-3699. E-mail address: mark.helou@breseight.com.au
Abstract
Additive manufacturing has opened doors to many new technological developments that could not be realised with traditional manufacturing
methods. One of these research areas includes the development and utilisation of Cellular Structures in everyday objects. The application of
cellular structures theoretically should decrease the required amount of material for production at the cost of overall rigidity and resistance to
stresses. This article presents a validation of Finite Element Analysis (FEA) simulations of Cellular Structures with empirical data obtained
from compression tests. Parametrised cells with two different materials are evaluated through FEA simulations against selective laser sintered
specimens. The cellular structure are modelled with implicit modelling method.
© 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
c 2016 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Selection and
Peer-review peer-review
under responsibilityunder
of theresponsibility of Professor
organizing committee Lihui
of the 26th Wang.
CIRP Design Conference
Keywords: Cellular Structure, Finite Element Analysis, Additive Manufacturing
2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of the 26th CIRP Design Conference
doi:10.1016/j.procir.2016.05.018
Mark Helou et al. / Procedia CIRP 50 (2016) 94 – 99 95
there is less material required to sinter in the DSLS and DSLM as well as decrease the overall cost of manufacturing a proto-
methods [2]. Significant amount of energy consumption re- type utilising advanced manufacturing machinery.
duces directly dependant on the surface area being laser sintered A significant amount of variance between empirical results
when compared to sintering a solid block of identical volume and simulation data has been found repeatedly between a va-
[6]. riety of studies which provide evidence of a cumulative error
The cellular structure design is especially important in ap- caused in different stages of the experiment procedure. [13]
plication due to its inherent high performance nature - pro- show that there is a significant error between the experimen-
ducing very high strength designs with relatively low mass. tal and theoretical elastic modulus of Nylon-12, whereas [14]
They also are extremely good at energy and shock absorption, demonstrate that there is a significant error between a numeri-
as well as well as being good thermal and acoustic insulators cal analysis simulation and traditional FEA modelling in SLS
[7]. Although the technology to manufacture structures at the due to the inability to describe the porosity of the sintered ma-
mesoscale and the microscale is increasingly becoming more terial in traditional FEA products.
advanced, there is an extremely large separation between tradi- However, the behaviour of selective laser sintered products
tional design and more advanced design that takes advantage of has not been examined in detail when they are applied to the
the additive manufacturing technologies such as SLS and SLM. manufacturing of cellular structures. This study aims to verify
There is a distinct lack of a rule of thumb during the design and further investigate the sources of errors in the FEA simula-
of cellular structures, which in turn causes a portfolio of exist- tion of cellular structures by using a range of cellular structure
ing cellular structures to be lacking, hampering the amount of types and examine the reasons of failure.
structures that can be implemented.
1.5. Organization of this Paper
1.3. Cellular Structure Generation
This paper outlines as follow. The generation of cellular
Existing methods of cellular structure generation typically structures, FEA, and manufacturing point of view are in Section
utilise a manual editing of geometry to achieve the final prod- 2. Experiments design and result are in Section 3. Discussion
uct. The procedure of creating a structure is usually automated and conclusion of this work are presented in Section 4-5.
[8], wherein the ends of the unit cell have their faces removed
and then are joined via a boolean technique with other cells to 2. Methodology
create a larger structure. This technique is also utilised in creat-
ing different cellular structure types [9], utilising cylinders and 2.1. Generation and Manufacturing
polyhedral geometric shapes to form innovative designs. These
recreation methods are various and well defined, however many In this study, a comparison between simulated and empirical
manual short cuts are taken in order to achieve a final product, compression tests are undertaken in order to compare the dif-
including repairs to geometrical errors by applying spherical ference between of SLS cellular structure blocks in reality and
junction at each node to smooth the connection and strengthen FEA. To conduct FEA on the cellular structures, they must first
the structure as it was built [9]. There exists also an innova- be modelled using approximations that accurately represent the
tive concept of Prefabrication Hybrid Geometry Modeling (P- family of structures. Once a representation is created, finite ele-
HGM) [10,11] that rapidly generates the cellular structure with ment modelling can be undertaken by applying approximations
boundary representation (B-Rep) and polygonal surface format, to the empirical testing scheme in order to generate data that
STL. can be compared.
The utilisation of implicit functions was introduced and re- The cellular structures, once generated, will be manufac-
sults in a much better performing structure in compression test- tured by using SLS and SLM. The SLS method sinters each
ing [2]. The utilisation of implicit functions such as triply pe- atomised particle of the powder together at each edge, unlike
riodic minimal surfaces become popular due to their ease of the SLM method which melts the powder into surrounding
manufacturability and the ability to change structure generation powder to form a mostly uniform object layer.
parameters in order to achieve optimal structure design for the
intended purpose [12].
2.2. Modelling method generation of cellular structure
1.4. FEA on Cellular Structures To generate each cellular structure, a building block, or unit
cell, has to be created as a seed for the final cube. Each triply
Although there is a large amount of research conducted on periodic minimalistic surface type that was to be utilised was
the generation of cellular structures, there is surprisingly lit- created with a trigonometric approximation. All solid files were
tle regarding the simulation of such structures using Finite El- generated in MATLAB 8.5 [15], utilising a variety of parame-
ement Analysis (FEA). The aim of this study is to explore the ters to create each cellular structure seed block through their
behaviour of FEA simulations conducted on cellular structure given equations. Two parameters - (a) the thickness of the cell
specimens via inverse testing, utilising data recorded from em- walls and (b) the seed unit cell length - can be varied in order to
pirical compression tests. Due to the extremely large cost asso- characterise the cellular structure.
ciated with rapid prototyping of projects for design verification The three different cellular structure types - namely Schoen
and testing, there is a need to utilise Finite Element Simulation Gyroid, Diamond, and Neovius (see Fig. 1) - are designed
in order to predict the behaviour of the device featuring cellular and produced to compare theoretical simulation and mechanical
structure design in order to reduce lead time in manufacturing testing results. The equations used for formulating the Schoen
96 Mark Helou et al. / Procedia CIRP 50 (2016) 94 – 99
3. Experiments
4x106 4x107
Stress (Pa)
Stress (Pa)
3x106 3x107
2x106 2x107
6 True Values 20mm 0.6mm PA2200 Diamond 7 True Values 20mm 0.7mm Stainless Steel Diamond
1x10 Simulation Results 1x10 Simulation Results
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.05 0.1 0.15 0.2 0.25 0.3
Strain (mm/mm) Strain (mm/mm)
Stress (Pa)
Stress (Pa)
6 7
3x10 3x10
6 7
2x10 2x10
True Values 20mm 0.6mm PA2200 Gyroid True Values 20mm 0.7mm Stainless Steel Gyroid
1x106 Simulation Results 1x107 Simulation Results
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.05 0.1 0.15 0.2 0.25 0.3
Strain (mm/mm) Strain (mm/mm)
4x106
True Values 20mm 0.6mm PA2200 Neovius 500000
Simulation Results
Stress (Pa)
Stress (Pa)
6 400000
3x10
300000
2x106
200000
True Values 18mm 0.7mm PA2200 Neovius
1x106 100000 Simulation Results
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.01 0.02 0.03 0.04 0.05
Strain (mm/mm) Strain (mm/mm)
4.3. Force
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