Numerical Simulation and Experimental Verification of UV-thermal Dual-cure Composites Part 3D Printing Process

doi:10.3901/JME.2023.15.293

Abstract

Abstract: Carbon fiber reinforced dual-curing polymer composites 3D printing process incorporates both the advantage of rapid free-form prototyping of additive manufacturing and the good mechanical properties of thermoset composites and then shows broad applications. In order to solve the problem of fatigue life reduction and joint assembly damage due to the residual stress in composites part caused in dual-curing process, a multi-physics theoretical model of UV-thermal dual-curing composite part forming is established, in which, the UV-curing kinetics, thermal curing kinetics and curing deformation are all considered. The effects of the sliced layer thickness in 3D printing, the volume fraction of the UV-curing resin in hybrid polymer composites, the carbon fiber content and the fiber aspect ratio on the deformation of the fabricated composites part in dual-curing process have been investigated. The corresponding experiments are performed and the correctness of the theoretical model and the simulation results are verified. The results show that increasing the sliced layer thickness and then reducing the total number of layers can reduce the stress-strain and deformation of the fabricated part. The increase of the content of UV-curing resin in the dual-curing resin will increase the deformation of the part. Increasing the carbon fiber volume fraction and fiber aspect ratio can reduce the expansion coefficient and deformation of the part. In this work, a multi-physics modeling and numerical calculation method for the UV- thermal dual-curing process of composite materials is proposed, the research results based on which can be used for process parameters optimization and then part fabrication quality improvement.

Key words: UV-thermal dual curing, 3D printing, multi physical field coupling, numerical simulation, warping deformation

CLC Number:

TB332

WANG Quandai, QIANG Haowen, YE Sitong, LI Pengyang, ZHENG Jianming, LI Yan. Numerical Simulation and Experimental Verification of UV-thermal Dual-cure Composites Part 3D Printing Process[J]. Journal of Mechanical Engineering, 2023, 59(15): 293-303.

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