Additively manufactured cylindrical systems with stiffness-tailored interface: Modeling and experiments

M. A. Khan; S. Kumar; Wesley J. Cantwell

doi:10.1016/j.ijsolstr.2018.06.002

Additively manufactured cylindrical systems with stiffness-tailored interface: Modeling and experiments

M. A. Khan, S. Kumar, Wesley J. Cantwell

Aerospace Engineering

Research output: Contribution to journal › Article › peer-review

23 Scopus citations

Abstract

The structural performance of multi-material bonded systems can be significantly improved by tailoring interfaces. Here, we report the performance of cylindrical bonded systems with stiffness-tailored interface both experimentally enabled by 3D printing, as well as by modeling. Stiffness-tailored systems are additively manufactured by engineering edge-compliance into the bondlayer. The deformation and failure behavior of 3D printed shaft-tube joints with such stiffness-tailored bondlayer was evaluated experimentally under axial tensile loads and was found to have about 40% and 25% more load carrying capacity and toughness, respectively, compared to joints with homogeneous bondlayer. A linear-elastic finite element (FE) model benchmarked with experimental results was employed to examine how the stress redistribution in the bondlayer due to stiffness-tailoring led to improved performance of graded joints. Motivated by the superior performance of stiffness-tailored joints, an analytical model for such joints is proposed within the purview of axisymmetric linear elastostatics. The effect of smoothly grading the interface properties of 3D printed shaft-tube joints on stress distribution is investigated and the influence of grading on shear-transfer length is identified using the developed model considering power-law variation of bondlayer's modulus along bondlength. A reduction in peak shear stress of about 45% was observed for systems with bondlength (l) greater than the shear-transfer length (l_cri) i.e., l ≥ l_cri for relatively stiff bondlayers. Subsequently, the stresses in more general class of bonded systems comprising metallic adherends and epoxy adhesive with power-law and exponential gradation schemes were analyzed. These gradation schemes were found to have a significant influence on stress redistribution along the bondlength of the adhesive providing guidelines for the optimal design of stiffness-tailored high performance bonded systems.

Original language	British English
Pages (from-to)	71-84
Number of pages	14
Journal	International Journal of Solids and Structures
Volume	152-153
DOIs	https://doi.org/10.1016/j.ijsolstr.2018.06.002
State	Published - Nov 2018

Keywords

3D printing
Bonded joints
Functionally graded materials
Stiffness tailoring
Tailored interfaces

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.ijsolstr.2018.06.002

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title = "Additively manufactured cylindrical systems with stiffness-tailored interface: Modeling and experiments",

abstract = "The structural performance of multi-material bonded systems can be significantly improved by tailoring interfaces. Here, we report the performance of cylindrical bonded systems with stiffness-tailored interface both experimentally enabled by 3D printing, as well as by modeling. Stiffness-tailored systems are additively manufactured by engineering edge-compliance into the bondlayer. The deformation and failure behavior of 3D printed shaft-tube joints with such stiffness-tailored bondlayer was evaluated experimentally under axial tensile loads and was found to have about 40% and 25% more load carrying capacity and toughness, respectively, compared to joints with homogeneous bondlayer. A linear-elastic finite element (FE) model benchmarked with experimental results was employed to examine how the stress redistribution in the bondlayer due to stiffness-tailoring led to improved performance of graded joints. Motivated by the superior performance of stiffness-tailored joints, an analytical model for such joints is proposed within the purview of axisymmetric linear elastostatics. The effect of smoothly grading the interface properties of 3D printed shaft-tube joints on stress distribution is investigated and the influence of grading on shear-transfer length is identified using the developed model considering power-law variation of bondlayer's modulus along bondlength. A reduction in peak shear stress of about 45% was observed for systems with bondlength (l) greater than the shear-transfer length (lcri) i.e., l ≥ lcri for relatively stiff bondlayers. Subsequently, the stresses in more general class of bonded systems comprising metallic adherends and epoxy adhesive with power-law and exponential gradation schemes were analyzed. These gradation schemes were found to have a significant influence on stress redistribution along the bondlength of the adhesive providing guidelines for the optimal design of stiffness-tailored high performance bonded systems.",

keywords = "3D printing, Bonded joints, Functionally graded materials, Stiffness tailoring, Tailored interfaces",

author = "Khan, {M. A.} and S. Kumar and Cantwell, {Wesley J.}",

note = "Funding Information: Authors gratefully acknowledge the financial support from the Abu Dhabi National Oil Company (ADNOC) under Award no: EX2016-000010. Authors would also like to thank Prof. Brian L. Wardle, Massachusetts Institute of Technology for his valuable comments and suggestions on the manuscript. Publisher Copyright: {\textcopyright} 2018",

year = "2018",

month = nov,

doi = "10.1016/j.ijsolstr.2018.06.002",

language = "British English",

volume = "152-153",

pages = "71--84",

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AU - Khan, M. A.

AU - Kumar, S.

AU - Cantwell, Wesley J.

N1 - Funding Information: Authors gratefully acknowledge the financial support from the Abu Dhabi National Oil Company (ADNOC) under Award no: EX2016-000010. Authors would also like to thank Prof. Brian L. Wardle, Massachusetts Institute of Technology for his valuable comments and suggestions on the manuscript. Publisher Copyright: © 2018

PY - 2018/11

Y1 - 2018/11

N2 - The structural performance of multi-material bonded systems can be significantly improved by tailoring interfaces. Here, we report the performance of cylindrical bonded systems with stiffness-tailored interface both experimentally enabled by 3D printing, as well as by modeling. Stiffness-tailored systems are additively manufactured by engineering edge-compliance into the bondlayer. The deformation and failure behavior of 3D printed shaft-tube joints with such stiffness-tailored bondlayer was evaluated experimentally under axial tensile loads and was found to have about 40% and 25% more load carrying capacity and toughness, respectively, compared to joints with homogeneous bondlayer. A linear-elastic finite element (FE) model benchmarked with experimental results was employed to examine how the stress redistribution in the bondlayer due to stiffness-tailoring led to improved performance of graded joints. Motivated by the superior performance of stiffness-tailored joints, an analytical model for such joints is proposed within the purview of axisymmetric linear elastostatics. The effect of smoothly grading the interface properties of 3D printed shaft-tube joints on stress distribution is investigated and the influence of grading on shear-transfer length is identified using the developed model considering power-law variation of bondlayer's modulus along bondlength. A reduction in peak shear stress of about 45% was observed for systems with bondlength (l) greater than the shear-transfer length (lcri) i.e., l ≥ lcri for relatively stiff bondlayers. Subsequently, the stresses in more general class of bonded systems comprising metallic adherends and epoxy adhesive with power-law and exponential gradation schemes were analyzed. These gradation schemes were found to have a significant influence on stress redistribution along the bondlength of the adhesive providing guidelines for the optimal design of stiffness-tailored high performance bonded systems.

AB - The structural performance of multi-material bonded systems can be significantly improved by tailoring interfaces. Here, we report the performance of cylindrical bonded systems with stiffness-tailored interface both experimentally enabled by 3D printing, as well as by modeling. Stiffness-tailored systems are additively manufactured by engineering edge-compliance into the bondlayer. The deformation and failure behavior of 3D printed shaft-tube joints with such stiffness-tailored bondlayer was evaluated experimentally under axial tensile loads and was found to have about 40% and 25% more load carrying capacity and toughness, respectively, compared to joints with homogeneous bondlayer. A linear-elastic finite element (FE) model benchmarked with experimental results was employed to examine how the stress redistribution in the bondlayer due to stiffness-tailoring led to improved performance of graded joints. Motivated by the superior performance of stiffness-tailored joints, an analytical model for such joints is proposed within the purview of axisymmetric linear elastostatics. The effect of smoothly grading the interface properties of 3D printed shaft-tube joints on stress distribution is investigated and the influence of grading on shear-transfer length is identified using the developed model considering power-law variation of bondlayer's modulus along bondlength. A reduction in peak shear stress of about 45% was observed for systems with bondlength (l) greater than the shear-transfer length (lcri) i.e., l ≥ lcri for relatively stiff bondlayers. Subsequently, the stresses in more general class of bonded systems comprising metallic adherends and epoxy adhesive with power-law and exponential gradation schemes were analyzed. These gradation schemes were found to have a significant influence on stress redistribution along the bondlength of the adhesive providing guidelines for the optimal design of stiffness-tailored high performance bonded systems.

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KW - Bonded joints

KW - Functionally graded materials

KW - Stiffness tailoring

KW - Tailored interfaces

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VL - 152-153

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JO - International Journal of Solids and Structures

JF - International Journal of Solids and Structures

ER -

Additively manufactured cylindrical systems with stiffness-tailored interface: Modeling and experiments

Abstract

Keywords

UN SDGs

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