Dynamic response of 3D printed functionally graded sandwich foams

• Published in: Rapid prototyping journal Vol. 29; no. 10; pp. 2257 - 2271
• Main Authors: Bonthu, Dileep, Bharath, H S, Bekinal, Siddappa I, Jeyaraj, P, Doddamani, Mrityunjay
• Format: Journal Article
• Language: English
• Published: Bradford Emerald Group Publishing Limited 27.11.2023
• Subjects: 3-D printers; Beams (structural); Boundary conditions; Buckling; Damping; Dynamic response; Energy consumption; Filaments; Fillers; Free vibration; Frequency variation; Functionally gradient materials; Fused deposition modeling; High density polyethylenes; Microballoons; Moisture absorption; Plastic foam; Polymer matrix composites; Rapid prototyping; Resonant frequencies; Sandwich structures; Stress concentration; Three dimensional printing
• ISSN: 1355-2546; 1758-7670
• DOI: 10.1108/RPJ-01-2023-0016

PurposeThe purpose of this study was to introduce three-dimensional printing (3DP) of functionally graded sandwich foams (FGSFs). This work was continued by predicting the mechanical buckling and free vibration behavior of 3DP FGSFs using experimental and numerical analyses.Design/methodology/approachInitially, hollow glass microballoon-reinforced high-density polyethylene-based polymer composite foams were developed, and these materials were extruded into their respective filaments. These filaments are used as feedstock materials in fused filament fabrication based 3DP for the development of FGSFs. Scanning electron microscopy analysis was performed on the freeze-dried samples to observe filler sustainability. Furthermore, the density, critical buckling load (Pcr), natural frequency (fn) and damping factor of FGSFs were evaluated. The critical buckling load (Pcr) of the FGSFs was estimated using the double-tangent method and modified Budiansky criteria.FindingsThe density of FGSFs decreased with increasing filler percentage. The mechanical buckling load increased with the filler percentage. The natural frequency corresponding to the first mode of the FGSFs exhibited a decreasing trend with an increasing load in the pre-buckling regime and an increase in post-buckled zone, whereas the damping factor exhibited the opposite trend.Originality/valueThe current research work is valuable for the area of 3D printing by developing the functionally graded foam based sandwich beams. Furthermore, it intended to present the buckling behavior of 3D printed FGSFs, variation of frequency and damping factor corresponding to first three modes with increase in load.