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Recently, 3D printing of large, structural polymer parts has received increasing interest, especially for the creation of recyclable structural parts and tooling. However, the complexity of large-scale 3D polymeric printing often dictates resource-intensive trial and error processes to achieve acceptable parts. Existing computational models used to assess the impact of fabrication conditions typically treat the 3D-printed part as a continuum, incorporate oversimplified boundary conditions and take hours to days to run, making design space exploration infeasible. The purpose of this study is to create a structural model that is computationally efficient compared with traditional continuum models yet retains sufficient accuracy to enable exploration of the design space and prediction of part residual stresses and deformations. To this end, a beam-based finite element methodology was created where beads are represented as beams, vertical springs represent inter-bead transverse force transfer and multi-point, linear constraints enforce strain compatibility between adjacent beads. To test this framework, the fabrication of a large Polyethylene terephthalate glycol (PETG) wall was simulated. The PETG was modeled as linearly elastic with an experimentally derived temperature-dependent coefficient of thermal expansion and elastic modulus using temperature history imported from an ABAQUS thermal model. The results of the simulation were compared to those from a continuum model with an identical material definition, showing reasonable agreement of stresses and displacements. Further, the beam-based model required an order of magnitude less run time. Subsequently, the beam-based model was extended to allow separation of the part from the printing bed and the inclusion of part self-weight during fabrication to assess the significance of these effects that pose challenges for existing continuum models. [ABSTRACT FROM AUTHOR]

In this paper, the mechanics of inflatable drop-stitch panels are investigated, including the impact of large shear deformations, nonlinearity due to wrinkling of the panel skin that occurs under net compressive strain, work done by the confined internal air, and the effect of the drop-stitch yarns on the panel skin stresses. A large deflection finite element (FE) analysis framework is presented that allows for a panel's stability and post-buckling response to be quantified. The FE code is verified through comparison with available analytical solutions, and the impact of critical response drivers is examined. The FE models are then used to explore the capacity of panel walls when used as part of a shelter subject to realistic wind and snow loads and to assess the dependence of the capacity on the important design parameters of inflation pressure and panel depth. The analyses indicate that while the drop-stitch panel capacity is sensitive to the panel depth and inflation pressure, panels with reasonable cross-sectional dimensions are viable for use in structural applications where they must support significant compression and bending. Future work should focus on increasing the structural efficiency and capacity by increasing the panel shear stiffness and operational inflation pressure. [ABSTRACT FROM AUTHOR]

This work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition process used in additive manufacturing, which corresponds to the repeated deposition of hot material onto cooler material, contributes to the presence of residual stresses and part warping. The prediction of these mechanisms is dependent on thermal history of the part, and the major motivation of this work was to improve the accuracy of finite element (FE) models used to quantify the thermal history of large-format additively manufactured parts. Thermocouples were placed throughout the part at varying heights to measure temperature as a function of time. The FE model developed found a thermal contact conductance between the printed part and the bed of 10 W/m2K and convection coefficient values that linearly varied from 3 to 15 W/m2K through the wall height when making a temperature comparison with the output from the thermocouples. It is also demonstrated that the FE model with a constant convection coefficient under-predicts model temperature at the beginning of the manufacturing process when compared against the model with a variable convection coefficient. The impact of this difference was seen in the stress values, which were larger for the model with a constant convection coefficient. Finally, a correlation equation was derived which allows the findings to be generalized to other vertical structures manufactured on the BAAM. In summary, this work offers valuable insights on material characterization, real-time thermocouple placement, and FE modeling of large-format additively manufactured parts. [ABSTRACT FROM AUTHOR]

This paper details the development and experimental assessment of a friction-type connector, designed to transfer shear flow between the top flange of a fiber-reinforced polymer (FRP) tub girder and a composite concrete deck for bridge applications. In contrast with previously used bearing-type connectors, this system relies on a deformed FRP surface to transfer shear via direct interlock with the concrete deck. The connector is materially efficient, simple to fabricate, can be used with lower-grade structural or stainless-steel fasteners, and provides a high degree of interface stiffness. Six compression-shear specimens were tested to assess the connector fatigue resistance and ultimate connection strength. Additionally, two short beam specimens were tested in three-point bending, one of which was subjected to fatigue loading. Based on the compression-shear tests and short beam tests, the connection exhibited strength exceeding that predicted by AASHTO for frictional concrete-concrete connections. The connection strengths were significantly greater than the factored demand required by AASHTO for a typical model FRP bridge girder. The cyclic loading of the connection in both compression-shear and beam bending showed that connection stiffness and strength do not significantly degrade, due to the application of 1 × 106 to 6 × 106 cycles of traffic-induced factored fatigue load. [ABSTRACT FROM AUTHOR]