Lectures Notes on Advanced Structured Materials

370 Pages·2022·14.315 MB·English

by  Holm Altenbach, Michael Johlitz, Markus Merkel, Andreas Öchsner

Advanced Structured Materials
Holm Altenbach
Michael Johlitz
Markus Merkel
Andreas Öchsner   Editors
Lectures Notes
on Advanced
Structured
Materials
Advanced Structured Materials
Volume 153
Series Editors
Andreas Öchsner, Faculty of Mechanical and Systems Engineering, Esslingen
University of Applied Sciences, Esslingen, Germany
Lucas F. M. da Silva, Department of Mechanical Engineering, Faculty of
Engineering, University of Porto, Porto, Portugal
Holm Altenbach , Faculty of Mechanical Engineering, Otto von Guericke
University Magdeburg, Magdeburg, Sachsen-Anhalt, Germany
Common engineering materials are reaching their limits in many applications, and
new developments are required to meet the increasing demands on engineering
materials. The performance of materials can be improved by combining different
materials to achieve better properties than with a single constituent, or by shaping
the material or constituents into a specific structure. The interaction between
material and structure can occur at different length scales, such as the micro, meso,
or macro scale, and offers potential applications in very different fields.
This book series addresses the fundamental relationships between materials and
their structure on overall properties (e.g., mechanical, thermal, chemical, electrical,
or magnetic properties, etc.). Experimental data and procedures are presented, as
well as methods for modeling structures and materials using numerical and
analytical approaches. In addition, the series shows how these materials engineering
and design processes are implemented and how new technologies can be used to
optimize materials and processes.
Advanced Structured Materials is indexed in Google Scholar and Scopus.
· ·
Holm Altenbach Michael Johlitz
·
Markus Merkel Andreas Öchsner
Editors
Lectures Notes on Advanced
Structured Materials
Editors
Holm Altenbach Michael Johlitz
Fakultät für Maschinenbau Institut für Mechanik
Otto-von-Guericke-Universität Magdeburg Universität der Bundeswehr München
Magdeburg, Sachsen-Anhalt, Germany Neubiberg, Germany
Markus Merkel Andreas Öchsner
Institute for Virtual Product Development Faculty of Mechanical and Systems
Aalen University of Applied Sciences Engineering
Aalen, Baden-Württemberg, Germany Esslingen University of Applied Sciences
Esslingen, Germany
ISSN 1869-8433 ISSN 1869-8441 (electronic)
Advanced Structured Materials
ISBN 978-3-031-11588-2 ISBN 978-3-031-11589-9 (eBook)
https://doi.org/10.1007/978-3-031-11589-9
© The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature
Switzerland AG 2022
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Preface
The postgraduate seminar series “Advanced Structured Materials: Development—
Manufacturing—Characterization—Applications” is designed to facilitate teaching
and informal discussion in a supportive and friendly environment. The seminar
provides a forum for postgraduate students to present their research results and train
their presentation and discussion skills, allows for extensive discussion of current
research being conducted in the wider area of advanced structured materials, builds a
wider postgraduate community and offers networking opportunities for early career
researchers.
The first seminar was held in the period 28 February till 3 March 2022 in Malta.
The four editors of this volume presented overview lectures related to composite
mechanics, experimental mechanics of polymers, additive manufacturing and clas-
sical plasticity theory. In addition, 21 postgraduate students attended this seminar
and presented their actual research projects. This volume contains the peer-reviewed
and revised versions of the submitted manuscripts.
Magdeburg, Germany Holm Altenbach
Neubiberg, Germany Michael Johlitz
Aalen, Germany Markus Merkel
Esslingen, Germany Andreas Öchsner
June 2022
v
Contents
Part I Overview Lectures
1 Composite Mechanics ......................................... 3
Holm Altenbach
1.1 Preliminary Remarks ..................................... 3
1.2 Definitions, Classifications and Applications ................. 5
1.3 Laminated Plates ......................................... 8
1.3.1 Description of Material Behaviour .................. 8
1.3.2 Modelling Levels ................................. 8
1.3.3 Modelling Based on Volume and Mass Fraction ....... 9
1.3.4 Combination of Both Approaches ................... 10
1.3.5 Elementary Mixture Rules ......................... 11
1.3.6 Effective Properties of a Single Layer ................ 14
1.3.7 Improved Formulas for Effective Moduli ............. 19
1.4 Particle-Reinforced Composites ............................ 20
1.4.1 Short-fibre-Reinforced Plastics ..................... 20
1.4.2 Spherical Inhomogeneity with Interphase ............. 21
1.5 Functionally Graded Materials ............................. 23
1.6 Anti-Sandwich and Nanomaterials .......................... 24
1.7 Summary and Outlook .................................... 24
References .................................................... 24
2 Aspects in the Modelling of Heterogeneous Thermo-Oxidative
Ageing Using the Example of a Rubber Buffer ................... 29
Bruno Musil and Michael Johlitz
2.1 Introduction ............................................. 29
2.2 Chemo-Thermo-Mechanical Simulation of a Rubber Buffer .... 31
2.2.1 Overview of the Quantities and Equations
of the Material Model ............................. 31
2.2.2 Results and Discussion ............................ 37
2.3 Experimental Investigation on Self-heating in Connection
with Ageing of a Rubber Buffer ............................ 40
vii
viii Contents
2.4 Conclusion .............................................. 42
References .................................................... 42
3 Digital Product Development by Additive Manufacturing ......... 45
Markus Merkel, Mario Rupp, and Michael Sedlmajer
3.1 Introduction ............................................. 45
3.2 AM-Process Within Digital Product Development
and Manufacturing ....................................... 46
References .................................................... 52
4 Theory of Three-Dimensional Plasticity ......................... 53
Andreas Öchsner
4.1 Comments on the Stress Matrix ............................ 53
4.2 Graphical Representation of Yield Conditions ................ 60
4.3 Yield Conditions ......................................... 64
4.3.1 Mises Yield Condition ............................. 65
4.3.2 Tresca Yield Condition ............................ 69
4.3.3 Drucker-Prager Yield Condition .................... 74
4.4 Flow Rule ............................................... 78
4.5 Hardening Rule .......................................... 78
4.5.1 Isotropic Hardening ............................... 78
4.5.2 Kinematic Hardening .............................. 79
References .................................................... 79
Part II Specialized Lectures
5 Influence of Silicon Content on the Mechanical Properties
of Additively Manufactured Al-Si Alloys ........................ 83
Enes Sert, Philippe du Maire, Elmar Schuch, Leonhard Hitzler,
Ewald Werner, and Andreas Öchsner
5.1 Introduction ............................................. 84
5.2 Experimental Methods .................................... 85
5.2.1 Sample Preparation ............................... 85
5.2.2 Chemical Analysis ................................ 86
5.2.3 Flowability ...................................... 86
5.2.4 Particle Size Distribution .......................... 87
5.2.5 Hardness ........................................ 88
5.2.6 Tensile Tests ..................................... 88
5.3 Results and Discussion .................................... 89
5.3.1 Chemical Analysis ................................ 89
5.3.2 Flowability ...................................... 89
5.3.3 Particle Size Distribution .......................... 91
5.3.4 Hardness ........................................ 92
5.3.5 Tensile Properties ................................. 93
5.4 Conclusions ............................................. 95
References .................................................... 95
Contents ix
6 Multi-step Additive Manufacturing Technologies Utilizing
the Powder Metallurgical Manufacturing Route .................. 99
Arne Davids, Lukas Apfelbacher, Leonhard Hitzler,
and Christian Krempaszky
6.1 Introduction ............................................. 100
6.2 Metal Additive Manufacturing ............................. 100
6.2.1 Single-Step AM Technologies ...................... 100
6.2.2 Multi-step AM Technologies ....................... 101
6.3 Summary ............................................... 112
References .................................................... 113
7 A Strategy to Extend the Limits of Unsupported Printing
in Laser Powder Bed Fusion by Optimized Process Parameters
Selection ..................................................... 119
Johannes Rottler, Christoph Petroll, Michael Johlitz,
Kristin Paetzold, and Alexander Lion
7.1 Introduction and Motivation ............................... 120
7.2 Laser Powder Bed Fusion Process .......................... 120
7.3 Support Structure ........................................ 122
7.4 Methods for Minimizing Support Structure ................... 123
7.5 Selecting Process Parameters in LPBF ....................... 124
7.5.1 State-of-the-Art Parameter Selection ................. 125
7.5.2 Parameter-Based Strategy to Minimize Support ....... 126
7.6 Conclusion .............................................. 128
References .................................................... 128
8 Influence of Relative Humidity on Thermal Properties of Tool
Steel Powder .................................................. 131
Garvin Schultheiss, Josef Tomas, and Markus Merkel
8.1 Introduction ............................................. 131
8.2 Methodology ............................................ 133
8.3 Experimental Setup ....................................... 134
8.4 Results ................................................. 134
8.5 Discussion .............................................. 136
8.6 Conclusion .............................................. 137
References .................................................... 137
9 An Overview on the 3D Printing of Elastomers
and the Influence of Printing Parameters on Their Mechanical
Properties .................................................... 139
Vivianne M. Bruère, Alexander Lion, Jens Holtmannspötter,
and Michael Johlitz
9.1 Introduction ............................................. 139
9.2 Overview on Additive Manufacturing ....................... 141
9.2.1 Definition and Technologies ........................ 141
9.2.2 Elastomers in 3D Printing .......................... 143
x Contents
9.2.3 FFF with Elastic Materials ......................... 145
9.3 Applied Case on FFF with a TPU Filament .................. 147
9.3.1 Experimental Procedure ........................... 147
9.3.2 Results and Discussion ............................ 148
9.4 Conclusions ............................................. 151
References .................................................... 152
10 Effects of Reusing Polyamide 12 Powder on the Mechanical
Properties of Additively Manufactured Parts .................... 155
Philippe du Maire, Enes Sert, Matthias Deckert, Michael Johlitz,
and Andreas Öchsner
10.1 Introduction ............................................. 156
10.2 Methodology ............................................ 157
10.3 Results and Discussion .................................... 160
10.4 Conclusion .............................................. 164
References .................................................... 165
11 On the Influence of Perimeter, Infill-Direction and Geometry
on the Tensile Properties of Test Specimen Manufactured
by Fused Filament Fabrication ................................. 167
Julian Klingenbeck, Alexander Lion, and Michael Johlitz
11.1 Introduction ............................................. 167
11.2 Research Focus .......................................... 171
11.3 Experimental Setup and Results ............................ 172
11.4 Discussion of Tensile Test Results .......................... 174
11.5 Conclusion .............................................. 179
References .................................................... 180
12 Design of a Room-in-Room Laboratory Environment
for the SLS Printing Process ................................... 183
Dominik Hahne, Alexander Lion, and Michael Johlitz
12.1 Motivation .............................................. 183
12.2 Mechanical Design of the Cabin ............................ 184
12.2.1 Design Structure .................................. 185
12.2.2 Structural Mechanics of the Cabin ................... 186
12.3 Thermal Concept ......................................... 189
12.4 Extraction System ........................................ 190
12.5 Summary ............................................... 192
References .................................................... 192
13 Chemical–Mechanical Characterization of Unaged and Aged
Additively Manufactured Elastomers ........................... 193
Yvonne Breitmoser, Sebastian Eibl, Tobias Förster,
Alexander Lion, and Michael Johlitz
13.1 Introduction ............................................. 193
13.2 Material ................................................ 194
13.3 Methods ................................................ 195