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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.

plastics, rubber and composites

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