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In this research, a method is examined by which the behavior of continuous carbon fiber reinforced additive manufacturing may be simulated using Finite Element Analysis. This technique is used in a simulated tensile test experiment in which the findings are compared to results determined from theoretical calculations according to the Rule of Mixtures method and from existing mechanical testing results. Four different fiber reinforcement configurations are examined with fiber volume fractions ranging from 4% to 32%. It was found that for fiber volume fractions of 11%, the simulation results closely match those predicted theoretically by the Rule of Mixtures as well as the mechanical testing results published in existing research. Lower fiber volume fractions near 4% yield less accurate results, with a 20% error due to the fact that the anisotropic behavior of the polymer matrix is the dominant material trait. Simulation of higher volume fractions near 32% closely approximate theoretical predictions, however neither the theoretical results nor the simulation results accurately reflect real world mechanical testing, indicating that nonideal condition factors such as the effect of micro-voids between the start and end of the fiber reinforcements play a significant role in the overall strength of the material. Thus, for fiber volume fractions near 11%, this simulation method can accurately be used to predict the behavior of end-use components, but more study must be done to increase simulation accuracy in low and high fiber volume fractions.

Validation of a finite element method for simulation of components produced by continuous carbon fiber reinforced additive manufacturing