Enhanced Energy Absorption with Bioinspired Composite Triply Periodic Minimal Surface Gyroid Lattices Fabricated via Fused Filament Fabrication (FFF)
Abstract
:1. Introduction
2. Materials and Methods
2.1. Lattice 3D CAD Design
2.2. Lattice Additive Manufacturing
2.3. Measurement of Density and Relative Density
2.4. Mechanical Compression of Lattice
Gibson–Ashby Model
2.5. SEM of Deformed and Undeformed Lattice
2.6. Finite Element Analysis (FEA) of Lattice
2.7. Energy Absorption
2.8. Case Study on Vehicle Crush Box Energy Absorption
3. Result and Discussion
3.1. Lattice Samples Density and POROSITY Measurement
3.2. The Mechanical Properties and Compressive Response
3.3. Plastic Plateau Stress and Young’s Modulus
3.4. Gibson–Ashby Power Fitting Analysis
3.5. Microstructure of Undeformed and Deformed Lattice Structure
3.6. FEM Simulation of Mechanical Compression and Validation of Stress–Strain Curve
Mesh Convergence STUDY
3.7. Energy Absorption
Maximum Energy Absorption and Densification Strain
3.8. Case Study on Composite TPMS Gyroid Latticed Crash Box
4. Conclusions
- A newly created composite TPMS gyroid lattice, created by Boolean subtraction, exhibits a deformation mode that is primarily bending, which is consistent with idealized gyroid and ligament-based TPMS behaviors.
- The 54% relative density crash box has a significantly shorter densification phase while having a larger strain energy storage capacity than the 33% and 38% relative density crash boxes, which show ideal energy absorption prior to densification.
- The findings suggest that the composite TPMS gyroid lattice, with its normalized stress and energy absorption, is an excellent model for fabricating foam structures from a class of PLA materials engineered for energy absorption.
- Our findings support the Gibson–Ashby model by confirming the significant influence of relative density on the mechanical properties of composite TPMS gyroid lattices. They also emphasize the importance of tailoring the lattice architecture to optimize energy absorption capabilities.
- A comprehensive force–displacement and strain energy–time analysis elucidates the mechanical behavior of latticed crash boxes when subjected to impact. This analysis has significance for the advancement of design and implementation in high-impact scenarios.
- According to the study, composite TPMS gyroid-latticed crash boxes with lower relative densities outperform in energy absorption and deformability, particularly at 25% density, which provides an optimal balance of displacement capacity and mechanical rigidity, promising improved crashworthiness for automotive safety applications.
Supplementary Materials
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Symbols | Descriptions |
---|---|
Density of the gyroid lattice structure, Kg/m3. | |
Density of the bulk materials from which the gyroid lattice is made, Kg/m3. | |
Volume fraction, or relative density, of the gyroid lattice; | |
Young’s modulus of gyroid lattice | |
Young’s modulus of the bulk materials from which the gyroid lattice is made. | |
Relative Young’s modulus of the Composite TPMS gyroid lattice, | |
Plateau Stress of composite TPMS gyroid lattice structure | |
The yield stress of the bulk materials from which the gyroid lattice is made. | |
Relative plateau stress of the gyroid lattice | |
Effective strain of the gyroid lattice structure | |
Engineering Stress of composite TPMS gyroid lattice structure | |
p | The porosity of the composite lattice |
Densification strain of composite TPMS gyroid lattice | |
MCG | Mass of composite TPMS gyroid lattice, kg |
WV | Energy absorption per volume of composite TPMS gyroid lattice, MJ/m3. |
η | Ideal energy absorption efficiency of composite lattice. |
γ | Efficiency of energy absorption by composite TPMS gyroid lattice. |
C | Gibson–Ashby constant. |
n | Gibson–Ashby exponent. |
Thickness of Sheet TPMS Gyroid (mm) | Thickness of Walled TPMS Gyroid (mm) | Composite TPMS Gyroid (ρ./ρPLA.) |
---|---|---|
0.4 | 1.2 | 14% |
0.3 | 1.0 | 25% |
0.25 | 0.75 | 33% |
0.2 | 0.6 | 38% |
0.1 | 0.1 | 54% |
Printing Parameters | Values |
---|---|
Printing speed | 50 mm/s |
Printing temperature | 205 °C |
Bed temperature | 65 °C |
Infill | 100% |
Extrusion width | 0.48 mm |
Filament diameter | 1.75 mm |
Raster angle | 45/−45 |
Property | Value | Testing Conditions |
---|---|---|
Density | 1.2 g/cm3 @ 21.5 °C | ASTM D792-ISO |
Young’s Modulus | 2636 ± 330 MPa | ASTM D638-ISO 527, Flat (X-Y) |
Tensile Strength | 46.6 ± 0.9 MPa | ASTM D638-ISO 527, Flat (X-Y) |
Elongation at Break | 1.90 ± 0.2% | ASTM D638-ISO 527, Flat (X-Y) |
Levels | Relative Density (%) | Replica |
---|---|---|
Solid PLA Cube | - | 3 |
GTL | - | 3 |
WGTL | - | 3 |
CTL14 | 14% | 3 |
CTL25 | 25% | 3 |
CTL33 | 33% | 3 |
CTL38 | 38% | 3 |
CTL54 | 54% | 3 |
Lattice Type | Measured Average Weight (g) | Actual Density (g/cm3) | Relative Density (%) | Porosity (%) |
---|---|---|---|---|
GTL | 20.38 ± 2.50 × 10−2 | 0.75 ± 1.93 × 10−3 | 61 | 39 |
WGTL | 13.08 ± 2.40 × 10−3 | 0.48 ± 4.10 × 10−4 | 39 | 61 |
CTL14 | 4.69 ± 2.38 × 10−3 | 0.17 ± 9.00 ×10−5 | 14 | 86 |
CTL 25 | 8.37 ± 1.87 × 10−2 | 0.31 ± 6.90 × 10−4 | 25 | 75 |
CTL 33 | 11.05 ± 2.06 × 10−2 | 0.41 ± 7.60 × 10−4 | 33 | 67 |
CTL 38 | 12.70 ± 2.10 × 10−2 | 0.47 ± 7.60 × 10−4 | 38 | 62 |
CTL 54 | 18.08 ± 2.51 × 10−2 | 0.67 ± 9.30 × 10−4 | 54 | 46 |
Elastic Modulus (MPa) | Plastic Plateau (MPa) | |||||
---|---|---|---|---|---|---|
Relative Density | Experiment | Simulation | Error (%) | Experiment | Simulation | Error (%) |
14% | 6.34 ± 0.10 | 5.96 ± 0.1 | 6.05 | 0.36 ± 0.10 | 0.36 ± 0.1 | 0.21 |
25% | 32.24 ± 0.35 | 30.10 ± 0.35 | 6.64 | 1.48 ± 0.35 | 1.48 ± 0.35 | 0.02 |
33% | 90.47 ± 1.08 | 83.62 ± 1.12 | 7.57 | 4.43 ± 1.08 | 4.44 ± 1.12 | 0.35 |
38% | 93.66 ± 1.08 | 87.27 ± 1.10 | 6.82 | 4.44 ± 1.08 | 4.45 ± 1.10 | 0.09 |
54% | 176.93 ± 3.75 | 163.98 ± 3.55 | 7.32 | 8.83 ± 3.75 | 8.83 ± 3.55 | 0.03 |
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Alemayehu, D.B.; Todoh, M. Enhanced Energy Absorption with Bioinspired Composite Triply Periodic Minimal Surface Gyroid Lattices Fabricated via Fused Filament Fabrication (FFF). J. Manuf. Mater. Process. 2024, 8, 86. https://doi.org/10.3390/jmmp8030086
Alemayehu DB, Todoh M. Enhanced Energy Absorption with Bioinspired Composite Triply Periodic Minimal Surface Gyroid Lattices Fabricated via Fused Filament Fabrication (FFF). Journal of Manufacturing and Materials Processing. 2024; 8(3):86. https://doi.org/10.3390/jmmp8030086
Chicago/Turabian StyleAlemayehu, Dawit Bogale, and Masahiro Todoh. 2024. "Enhanced Energy Absorption with Bioinspired Composite Triply Periodic Minimal Surface Gyroid Lattices Fabricated via Fused Filament Fabrication (FFF)" Journal of Manufacturing and Materials Processing 8, no. 3: 86. https://doi.org/10.3390/jmmp8030086