Estudo experimental de parâmetros de impressão e otimização de peças em manufatura aditiva

Abstract

Topological optimization, which suffers from the limitations of traditional manufacturing, has been increasingly applied due to additive manufacturing. Thus, the main objective of the present work was to develop a comparison between optimization methods derived from additive manufacturing through fused filament fabrication (infill variation) and topological optimization (SIMP method). For this purpose, tensile tests were initially carried out with variation of printing angle, material supplier, extrusion rate, printing speed, and filament width, on specimens obtained by this manufacturing method. Then, after finding the best parameters for the levels considered, an optimized part was developed and printed for testing under compression. Finally, the experimental results were used for the development of a numerical analysis of the parts. It became clear that the best parameters were filaments oriented parallel to the loading direction, the material from supplier 1, the smaller extrusion width, the lower printing speed, and the higher extrusion rate. Accordingly, the specimen with the best levels achieved a tensile strength of 62.78 MPa, while the one with the lowest levels obtained 31.85 MPa. Notably, the extrusion rate was the parameter that most influenced the mechanical behavior, followed by the printing angle of the filaments. The optimization analyses demonstrated a clear superiority in the mechanical strength of parts optimized by topological optimization compared to other optimization types; the part to which topological optimization was applied reached a maximum force value above 12 kN, while the one obtained using grid infill achieved around 9 kN, and the one obtained using gyroid infill reached less than 6 kN. Finally, the numerical simulations demonstrated the reliability of the methodology employed, as the stress concentration markings coincided with the rupture locations during experimental testing. In addition, they highlighted the smoothing effect caused by additive manufacturing in relation to irregular geometries.