A method of failure modeling for 3D printed cellular structures

Abstract The paper presents a new approach for failure modeling of a cellular structure manufactured with a 3D printing technology. For this purpose, the honeycomb topology was designed and fabricated using fused deposition modeling of ABSplus material. The proposed method was based on the tiebreak contact for connecting plastic joints with cell walls. Additionally, two methods based on constitutive models were also analyzed. In the first case, an elasto-plastic material model was adopted, whereas in the second case an elasto-visco-plastic material model with damage was included. Firstly, the mechanical properties of ABSplus material were determined and numerically correlated with experimental outcomes. Subsequently, a contact parametric study was performed, and the optimal contact parameters were evaluated. The quasi-static experimental compression tests were simulated using LS-Dyna software. The results of actual tests and numerical analyses with three different methods for honeycomb structure modeling were compared in terms of deformation, force history, failure behavior and energy absorption capabilities. It was shown that the contact-based method resulted an in an increase of the results quality with better reproduction of force characteristic and progressive failure behavior during the deformation process, compared to other two methods.