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A COHESIVE ZONE MODEL FOR THE STAMPING PROCESS ENCOUNTERED DURING 3D PRINTING OF FIBER-REINFORCED SOFT COMPOSITES

[+] Author and Article Information
Clayson C. Spackman

Graduate Research Assistant, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, 110 Eighth Street, Troy, NY 12180, USA
spackc@rpi.edu

James F. Nowak

Graduate Research Assistant, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, 110 Eighth Street, Troy, NY 12180, USA
nowakj2@rpi.edu

Kristen Mills

Assistant Professor, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, 110 Eighth Street, Troy, NY 12180, USA
millsk2@rpi.edu

Johnson Samuel

Associate Professor, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, 110 Eighth Street, Troy, NY 12180, USA
samuej2@rpi.edu

1Corresponding author.

ASME doi:10.1115/1.4037603 History: Received December 28, 2016; Revised August 01, 2017

Abstract

The 3D printing of fiber-reinforced soft composites (FrSCs) is a layer-by-layer material deposition process that alternates between inkjet deposition of an ultraviolet (UV) curable polymer layer and the stamping of electrospun fibers onto the layer, to build the final part.While this process has been proven for complex 3D geometries, it suffers from poor fiber transfer efficiencies that affect the eventual fiber content in the printed part. In order to address this issue, it is critical to first understand the mechanics of the fiber transfer process. To this end, the objective of this paper is to develop a cohesive zone-based finite element model that captures the competition between the 'fiber-carrier substrate' adhesion and the 'fiber-polymer matrix' adhesion, encountered during the stamping process used for 3D printing FrSCs. The cohesive zone model parameters are first calibrated using independent micro-scale fiber peeling experiments involving both the thin-film aluminum carrier-substrate and the UV curable polymer matrix. The predictions of the calibrated model are then validated using fiber transfer experiments. The model parametric studies suggest the use of a roller-based stamping unit design to improve the fiber transfer efficiency of the FrSC 3D printing process. Preliminary experiments confirm that for a 0.5 inch diameter roller, this new design can increase the fiber transfer efficiency to ~97%, which is a substantial increase from the 55% efficiency value seen for the original flat-plate stamping platen design.

Copyright (c) 2017 by ASME
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