Experimental study on the 3D‐printed plastic parts and predicting the mechanical properties using artificial neural networks

This study investigates the mechanical properties of 3D‐printed plastic parts fabricated using Fused Deposition Modeling (FDM). For this purpose, a 3D printer named KASAME was designed and built by the researchers. The test samples were fabricated using polylactic acid (PLA). The experiments were conducted using three melt temperatures (190°C, 205°C, and 220°C), four layer thickness values (0.06 mm, 0.10 mm, 0.19 mm, and 0.35 mm), and three raster pattern orientations (+45°/?45° [the crisscross pattern], horizontal and vertical). Tensile strength tests were performed to determine tensile strength values of the samples and fracture surfaces were also analyzed. Using artificial neural networks, a mathematical model for the tensile test results was generated corresponding to the raster pattern employed in 3D fabrication. Tensile strength tests indicated that melt temperature, layer thickness, and raster pattern orientation had a significant effect on the tensile strengths of the samples. According to the result of the experiment, the maximum average tensile strength values were observed for the samples fabricated using the crisscross raster pattern. The analysis of variance (ANOVA) table shows the raster pattern (PCR) value of 48.68% was obtained with the highest degree of influence. With respect to R ², the best performing artificial neural network model, with test and training values of 0.999199 and 0.999997, respectively, was observed to be the crisscross raster pattern. Copyright © 2016 John Wiley & Sons, Ltd.     

Fabrication of open‐porous PCL/PLA tissue engineering scaffolds and the relationship of foaming process,morphology, and mechanical behavior

Tissue engineering scaffolds should provide a suitable porous structure and proper mechanical strength, which is beneficial for the delivery of growth factor and regulation of cells. In this study, the open‐porous polycaprolactone (PCL)/poly (lactic acid) (PLA) tissue engineering scaffolds with suitable porous scale were fabricated using different ratios of PCL/PLA blends. At the same time, the relationship of foaming process, morphology, and mechanical behavior in the optimized batch microcellular foaming process were studied based on the single‐factor experiment method. The porous structures and mechanical strength of the scaffolds were optimized by adjusting foaming parameters, including the temperature, pressure, and CO₂ dissolution time. The results indicated that the foaming parameters influence the cell morphology, further determine the mechanical behavior of PCL/PLA blends. When the PCL content is high, with the increase of temperature and time, the cell diameter and the elastic modulus increased, and the tensile strength and elastic modulus increased with the increase of the average cell size, and decreased as the increase of the cell density. While when the PLA content was high, the cell diameter showed the same trend, and the tensile strength and elastic modulus were higher, and the elongation at break was lower, and tensile strength and elastic modulus decreased with the increase of the average cell size and increased with the increase of cell density. This work successfully fabricated optimized porous PCL/PLA scaffolds with excellent suitable mechanical properties, pore sizes, and high interconnectivity, indicating the effectiveness of modulating the batch foaming process parameters.     

Deformation and microstructure of extended-chain polydiacetylene crystals

The mechanical properties (Young's modulus, ultimate tensile strength, deformation processes) of extended-chain polydiacetylene crystals are investigated. The properties observed are similar to those of metal and ceramic whiskers. The elastic modulus is strain-dependent and the ultimate tensile strength increases with decreasing crystal size. The maximum tensile strength observed was 1700 Nmm^?2. The ultimate tensile strength seems to be controlled by the presence of a small number of defects near the surface at which fracture nucleates. Irreversible deformation of the crystals was observed to occur by crack propagation normal and parallel to the direction of the macromolecules. The observed mechanical behavior corresponds to exceptionally high per-chain properties. The per-chain modulus obtained for these crystals is nearly as high as that of diamond. A chain-aligned polyethylene fiber with the same per-chain mechanical properties would have an ultimate strength as high as 0.9 × 10⁴ Nmm^?2.     

The effects of surface treated carbon fibers and CaCO<Subscript>3</Subscript> nanoparticles inclusions on the mechanical performances of PA6/ABS-based composites

The mechanical and morphological characteristics of PA6/ABS (60/40)-based hybrid composite containing HNO₃-treated short carbon fibers (HSCF) and CaCO₃ nanoparticles have been experimentally studied. A counter-rotating twin-screw extruder and an injection molding machine were employed to produce different samples containing 10 wt % of HSCF and 0, 2, 5 and 8 wt % of CaCO₃ nanoparticles. The SEM observations indicated high-quality adhesion between HNO₃-surface treated carbon fibers and PA6/ABS polymer matrix. In addition, the morphological studies showed that the inclusion of CaCO₃ nanoparticles caused a significant effect on the ABS particle dispersion in PA6/ABS matrix. The mechanical properties assessments revealed that the incorporation of 10 wt % HSCF into the PA6/ABS can significantly improve tensile strength (82%), tensile modulus (107%), flexural strength (98%), flexural modulus (104%) and impact resistance (24%). The inclusion of CaCO₃ nanoparticles, in the presence of 10 wt % HSCF, led to the noticeable improvements of tensile strength (128% for 2 wt % CaCO₃), tensile modulus (199% for 5 wt % CaCO₃), flexural strength (146% for 5 wt % CaCO₃), flexural modulus (204% for 5 wt % CaCO₃) and impact resistance (46% for 2 wt % CaCO₃). The surface treatment of carbon fibers, dispersion conditions of nanoparticles and ABS phase in polymeric matrix were found to be the major important factors affecting the mechanical properties.     

Mechanical evaluation of polymeric filaments and their corresponding 3D printed samples

3D printing technologies permits to produce functional parts with complex geometries, optimized topologies or enhanced internal structures. The relationship between mechanical performance and manufacturing parameters should be exhaustively analyzed to warrant the long term success of printed products. In this work, the mechanical performance of filaments based on acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and polylactic acid/polyhydroxyalkanoate (PLA/PHA) was investigated and also compared with their corresponding 3D printed samples. In general, the specimen dimensional deviations were found to be within the tolerances defined by the standard testing protocols. Density values revealed a high level of filament fusion promoting a nearly solid internal structure. The filaments exhibited improved tensile performance with respect to their corresponding printed samples. Tensile and bending performance looked quite independent of the raster angle. Izod impact behavior was increased, for ABS systems printed with the ±45° raster orientation. Quasi-static fracture tests displayed improved crack initiation resistance with the 0°/90° raster angle. The crack propagation observed for the ±45° specimens, through the bonding of the inter-layers, suggests weak entanglements.     

Effects of raster angle on the mechanical properties of PLA and Al/PLA composite part produced by fused deposition modeling

This paper studies the mechanical properties of polylactic acid (PLA) and aluminum fiber–reinforced PLA composite (Al/PLA) specimens fabricated by fused deposition modeling (FDM) process. The effect of raster angle (0°, 90°, 45°, 0°/90°, and ± 45°) on dynamic mechanical thermal property and tensile property of FDM‐printed PLA and Al/PLA has been studied. The results show reduced tensile strength and Young's modulus in Al/PLA composite specimen in comparison with pure PLA specimen. However, the elongation‐at‐break increases, which is due to Al fiber with the higher elasticity and lower tensile strength than PLA. The addition of Al fibers improves the dynamic mechanical thermal property of pure PLA because of the good interaction of the PLA matrix with the surrounding Al fibers. Raster angle plays an important role in FDM process. All specimens printed with 0° raster angle show highest tensile strength and dynamic mechanical properties, while specimens printed with 90° raster angle have the lowest values. Fractured surfaces indicate that the failure of the specimen with 0° raster angle is due to breaking of individual layers, while for 90° raster angle, specimen fails under separation of the adjacent raster layers.     

Mechanical behavior of polyester polymer concrete under low strain rate loading conditions

Polymer concrete (PC) has superior mechanical properties in comparison with cement concrete. In this research, the mechanical behavior of polyester polymer concrete (PPC) and its polyester resin were studied at different loading rates. Special specimens for testing the PPC and the polyester resin under low strain rate loading conditions were fabricated. Experiments were performed under different strain rates, from 0.00033 to 0.15 s⁻¹, and results for the PPC and the polyester resin were compared. Furthermore, the influence of strain rate on the mechanical response of the neat polyester and the PPC was investigated. The results show a maximum 40% increase in tensile strength of the neat polyester, while the elastic modulus does not change significantly. The compressive strength of the PPC increases by 25%. These results show that the mechanical behavior of the polyester resin and its PC is extremely sensitive to the strain rate.     

Evaluation of the SEBS copolymer in the compatibility of PP/ABS blends through mechanical,thermal, thermomechanical properties,and morphology

Polypropylene (PP) blends with acrylonitrile-butadiene-styrene (ABS) were prepared using the styrene-ethylene-butylene-styrene copolymer (SEBS) as a compatibilizing agent. The blends were prepared in a co-rotational twin-screw extruder and injection molded. Torque rheometry, Izod impact strength, tensile strength, heat deflection temperature (HDT), differential scanning calorimetry, thermogravimetry, and scanning electron microscopy properties were investigated. The results showed that there was an increase in the torque of PA6/ABS blends with SEBS addition. The PP/ABS/SEBS (60/25/15%) blend showed significant improvement in impact strength, elongation at break, thermal stability, and HDT compared with neat PP. The elastic modulus and tensile strength have not been significantly reduced. The degree of crystallinity and the crystalline melting temperature increased, indicating a nucleating effect of ABS. The PP/ABS blends compatibilized with 12.5% and 15% SEBS presented morphology with well-distributed fine ABS particles with good interfacial adhesion. As a result, thermal stability has been improved over pure PP and the mechanical properties have been increased, especially impact strength. In general, the addition of the SEBS copolymer as the PP/ABS blend compatibilizer has the advantage of refining the blend's morphology, increasing its toughness and thermal stability, without jeopardizing other PP properties.     

Stress relaxation of PVC below the yield point

Stress relaxation of commercial poly(vinyl chloride) (PVC) is measured at strains below 3% and at different temperatures below the glass transition temperature. First it is shown that below the yield point the material follows a linear viscoelastic behavior. Then the data at a fixed deformation level (0.03) are fitted by considering a lognormal distribution function of relaxation times. Furthermore, from the measured stress-strain curves, the temperature dependence of the elastic tensile modulus is determined. The temperature dependence of the elastic modulus, the relaxation strength, and the parameters of the distribution: mean relaxation time, τ_m, and half-width, β, are given. Moreover, the distribution function and the temperature dependence of its characteristic parameters are discussed in terms of a cooperative model of the mechanisms involved in the mechanical relaxation of glassy polymers. Finally, the relationship proposed between the tensile modulus and the free volume helps explain the temperature dependence of the relaxation strength. © 1996 John Wiley & Sons, Inc.     

Effect of hybrid fillers on the mechanical behavior of polypropylene based hybrid composites

The present study investigates the effect of hybrid fillers such as graphene nanoplatelets (GnPs) and Titanium di-oxide (TiO₂) in polypropylene (PP) composites on the mechanical properties. The compatibilizing agent of Maleic anhydride grafted polypropylene (MAPP) are used in the polypropylene based composites to increase the interfacial adhesion between matrix and fillers. The experiments are designed according to L₁₆ orthogonal array (OA) based design of experiments (DOE). The parameters selected for this study are GnPs, TiO₂ and MAPP with four different levels are used.By using Orthogonal array and Taguchi based experimental design, the performance characteristics of tensile modulus, tensile strength, elongation at break and toughness can be analyzed with more objective through a small set of experiments.Taguchi based analysis are used to find out the optimal parameters to maximize the tensile properties for the GnPs and TiO₂ reinforced PP hybrid composites. Further, analysis of variance (ANOVA) is investigated to identify the most significant parameters which influence the mechanical properties.From the analysis it was found that the optimal parameters of 3 ?wt% GnPs, 2 ?wt% TiO₂ and 6 ?wt% MAPP for maximum tensile modulus and tensile strength. The most significant parameter for tensile modulus and tensile strength is GnPs followed by TiO₂ and MAPP according to ANOVA analysis.     

Application of artificial neural network to evaluation of dimensional accuracy of 3D-printed polylactic acid parts

Additive manufacturing (AM) has begun to replace traditional fabrication because of its advantages, such as easy manufacturing of parts with complex geometry, and mass production. The most important limitation of AM is that dimensional accuracy cannot be achieved in all parts. Dimensional accuracy is essential for high reliability, high performance, and useful final products. This study investigates the impact of printing parameters on the dimensional accuracy of samples fabricated through fused deposition modeling (FDM), an additive manufacturing (AM) method utilizing polylactic acid (PLA) material. The experimental design process was performed using Taguchi methodology. ANOVA was used to determine the most important parameter affecting accuracy. Based on experimental studies, the optimal printing parameters for parts are determined as follows: concentric infill pattern, 3 mm wall thickness, 70% infill density, and a layer thickness of 200 μm. Artificial neural network (ANN) was used in the evaluation and prediction of the results. The R-square (R²) performance evaluation criterion was above 95% from the ANN results. This value shows that the results are significant. The data acquired from this study may assist in identifying optimal parameters that contribute to the fabrication of samples with high dimensional accuracy using the FDM method.     

Evolution of structural features and mechanical properties during the conversion of poly[(methylamino)borazine] fibers into boron nitride fibers

Poly[(methylamino)borazine] (PolyMAB) green fibers of a mean diameter of 15 μm have been pyrolyzed under ammonia up to 1000°C and heat treated under nitrogen up to 2000°C to prepare boron nitride (BN) fibers. During the polymer-to-ceramic conversion, the mechanical properties of the green fibers increase within the 25-400°C temperature range owing to the formation of a preceramic material and remain almost constant up to 1000°C. Both the crystallinity and the mechanical properties slightly increase within the 1000-1400°C range, in association with the consolidation of the fused-B₃N₃ basal planes. A rapid increase in tensile strength (σ^R) and elastic modulus (Young's modulus E) is observed in relation with crystallization of the BN phase for fibers treated between 1400°C and 1800°C. At 2000°C, “meso-hexagonal” BN fibers of 7.5 μm in diameter are finally obtained, displaying values of σ^R=1.480 GPa and E=365 GPa. The obtention of both high mechanical properties and fine diameter for the as-prepared BN fibers is a consequence of the stretching of the green fibers on a spool which is used during their conversion into ceramic.     

Analysis of the area of material really tested by TMA

Deformation distribution within the specimen beneath the thermomechanical analysis (TMA) probe, found by using the finite element method (FEM), depends mainly on penetration depth, specimen thickness and diameter as well as on radius of the probe tip when the Poisson’s ratio influences it just slightly. For standard radius of the tip R_o=1 mm, most deformation is distributed in a material layer up to 0.5 mm thick independently on elastic modulus of a polymer at a glassy state. It is caused by the fact that maximal penetration depth for the polymers usually equals to about 0.05 mm. Because of this, the contact surface area is less than 0.17 mm² for the standard radius of the tip. This evidences that predominantly the specimen volume equal to  mm² (depth×area) is tested by the TMA at compression mode. For R_o=5 mm is tested the layer 2.5 mm thick. This makes possible to evaluate the material properties in the zone of different thickness depending on radius of the tip.     

Tensile properties of semi-crystalline thermoplastic polymers: Effects of temperature and strain rates

This work deals with the study of temperature and time dependency of tensile properties of a PA 12-based polymer. The range of variation of parameters in experiments was linked to in-service conditions of components manufactured with this material (temperature interval from ?25 °C to 50 °C and average strain-rate magnitudes from 0.00028 s^?1 to 9.4 s^?1). For tests with different temperatures and low speed, an electro-mechanical machine, Zwick Z250, equipped with an incremental extensometer was used. To study the effect of strain rate at medium speeds, a servo-hydraulic system, Schenk PC63M, equipped with a strain-gauge extensometer was used, while at high speeds a servo-hydraulic machine, Instron VHS 160/20, equipped with a high-speed camera for strain evaluation by digital image correlation was employed. The changes of the rate of deformation with strain as well as elastic modulus variation with strain were studied. An increase in the elastic modulus and yield strength was observed with a drop in temperature and an increase in the strain-rate, temperature having a stronger influence on the variation of mechanical properties. The collected data was assembled in an elasto-plastic material model for finite-element simulations capable of rendering temperature- and strain-rate-dependency. The model was implemented in the commercial software Abaqus, yielding accurate results for all tests.     

Preparation and properties of antibacterial ABS plastics based on polymeric quaternary phosphonium salts antibacterial agents

Antibacterial acrylonitrile‐butadiene‐styrene (ABS) plastics were prepared by adding polymeric quaternary phosphonium salts as antibacterial agents through a double screw extruder. The novel polymeric quaternary phosphonium salts (PBrMAP‐n) with alkyl chain length ranging from 3 to 11 were synthesized, and their chemical structures were confirmed by Nuclear magnetic resonance hydrogen spectroscopy (¹H‐NMR) and Fourier transform infrared spectroscopy (FT‐IR) spectra. The thermogravimetric analysis (TGA) results showed that all of the antibacterial agents had good thermal stability. The influence of addition amount as well as the alkyl chain length on mechanical properties and antibacterial properties was investigated. Compared with the pure ABS, all of PBrMAP‐n containing specimens had comparable tensile strength and flexural properties but reduced impact strength. Only samples with 10 wt% of PBrMAP‐11 exhibited more than 90% antibacterial efficiency against Escherichia coli and Staphylococcus aureus.     

The electrospun poly(ε‐caprolactone)/fluoridated hydroxyapatite nanocomposite for bone tissue engineering

Biodegradable cell‐incorporated scaffolds can guide the regeneration process of bone defects such as physiological resorption, tooth loss, and trauma which medically, socially, and economically hurt patients. Here, 0, 5, 10, and 15 wt% fluoridated hydroxyapatite (FHA) nanoparticles containing 25 wt% F^? and 75 wt% OH^? were incorporated into poly(ε‐caprolactone) (PCL) matrix to produce PCL/FHA nanocomposite scaffolds using electrospinning method. Then, scanning electron microscopy (SEM), X‐ray diffraction (XRD) pattern, and Fourier transform infrared spectroscopy (FTIR) were used to evaluate the morphology, phase structure, and functional groups of prepared electrospun scaffolds, respectively. Furthermore, the tensile strength and elastic modulus of electrospun scaffolds were investigated using the tensile test. Moreover, the biodegradation behavior of electrospun PCL/FHA scaffolds was studied by the evaluation of weight loss of mats and the alternation of pH in phosphate buffer saline (PBS) up to 30 days of incubation. Then, the biocompatibility of prepared mats was investigated by culturing MG‐63 osteoblast cell line and performing MTT assay. In addition, the adhesion of osteoblast cells on prepared electrospun scaffolds was studied using their SEM images. Results revealed that the fiber diameter of prepared electrospun PCL/FHA scaffolds alters between 700 and 900 nm. The mechanical assay illustrated the mat with 10 wt% FHA nanoparticles revealed the highest tensile strength and elastic modulus. The weight loss alternation of mats determined around 1% to 8% after 30 days of incubation. The biocompatibility and cell adhesion of mats improved by increasing the amounts of FHA nanoparticles.     

Effects of fused deposition modeling process parameters on tensile,dynamic mechanical properties of 3D printed polylactic acid materials

Fused deposition modeling (FDM) is an important process among the available additive manufacturing technologies in various industries. Although there exists many works investigating the effects of FDM process parameters on the mechanical properties of printed materials, there are still several points need to be studied. One is the effects of process parameters on the dynamic mechanical properties of FDM-printed materials, especially in environments where the temperature often changes. The other is the mechanism by which process parameters affect the mechanical properties of printed materials. Aiming at these two points, uniaxial tensile tests and dynamic mechanical analysis are carried out respectively to characterize the tensile properties and dynamic mechanical properties of FDM-printed PLA materials under different FDM process parameters, namely printing angle, layer thickness, fill rate and nozzle temperature. Based on the experimental results explanations are given for the influence of the FDM process parameters on the mechanical properties of the printed materials.     

Statistical analysis of mechanical properties of wood-PLA composites prepared via additive manufacturing

Additive manufacturing circumscribes numerous technologies that allow for the construction of three-dimensional parts by superimposing layers of material. These technologies have undergone greater development in recent years. In this work, using 3D additive printing technology, the samples are prepared using biodegradable wood-PLA composite by varying the layer height (0.08?mm, 0.16?mm, and 0.24?mm), infill (30%, 60%, and 90%) and three different patterns such as layer, triangle, and hexagon. Using universal testing machines tensile properties, energy absorption, and toughness of samples are evaluated as per ASTM standards. The results show that better values are achieved with increase in the infill percentage and layer pattern provides better strength and stiffness. A statistical linear regression model was successfully developed to predict the mechanical properties with an accuracy of 96% predicted in layer pattern when compared to other. Linear regression method helps to find the relationships between two sub-properties of mechanical property of different types of materials and helps to predict the properties of unknown materials.     

Utilization of waste tire rubber in hybrid plywood composite panel

The aim of this work was to use waste tire rubber (WTR) in the middle layer of hybrid plywood materials. The effects of four variable parameters, namely, WTR contents (430 and 720 g), resin contents (120 and 160 g/m²), hot pressing (single‐stage and two‐stage), and arrangements of veneer layers on the mechanical, physical, and acoustical properties, were studied. Beech (Fagus orientalis) and alder (Alnus glutinosa) veneers having 1.8‐mm thickness were used in the production of hybrid plywood panels. Rubber layers of 3‐ and 5‐mm thickness were used in the middle layer of plywood samples. To produce plywood panels, single‐stage and two‐stage hot‐pressing processes were used. Bonding of wood layers was performed using 120 and 160 g/m² urea‐formaldehyde resins, and to form the rubber layers and bond them to wood layers, methylene diisocyanate resin (150 g/m²) was used. Overall trend showed that with the increase in rubber content, the physical properties (water absorption, thickness swelling, and sound absorption) of the manufactured panels were improved, while the mechanical properties (modulus of rapture, modulus of elasticity, and impact strength) of the panels were reduced. Both physical and mechanical performances of plywood panels were improved with increase in resin content. An increase in the WTR content in plywood improved the composite's acoustical property. The production process of the wood/rubber plywood did not significantly affect their properties. The order of improvement in the physical properties of the panels is rubber content > resin content > arrangement of layers > pressing process. Copyright © 2015 John Wiley & Sons, Ltd.     

The tensile properties of HNO3‐treated carbon fiber reinforced ABS/PA6 composites

In this study, acrylonitrile‐butadiene‐styrene (ABS) terpolymer was reinforced with HNO₃‐treated short carbon fibers (SCFs) [(hollow carbon fibers (HCFs)]. The effects of HCF concentration on the tensile properties of the composites were examined. Increasing the HCF concentration in the ABS matrix from 10 to 30 wt% resulted in improved tensile strength and tensile modulus. To obtain a strong interaction at the interface, polyamide 6 (PA6) at varying concentrations was introduced into the ABS/10 wt% SCF composite. The incorporation and increasing amount of PA6 in the composites increased tensile properties of the ABS/PA6/HCF systems due to the improved adhesion at the interface, which was confirmed by the ratio of tensile strength as an adhesion parameter. These results were also supported by scanning electron micrographs of the ABS/PA6/HCF composites, which exhibited an improved adhesion between the SCFs and the ABS/PA6 matrix. Copyright © 2009 John Wiley & Sons, Ltd.