Predicting the Performance of Flexible Multi-material Additively Manufactured Beam Structures Under Small and Large Deflections
Restricted (Penn State Only)
- Author:
- Thomas, Evelyn
- Graduate Program:
- Engineering Design
- Degree:
- Master of Science
- Document Type:
- Master Thesis
- Date of Defense:
- April 28, 2023
- Committee Members:
- David Mazyck, Program Head/Chair
Jared Butler, Thesis Advisor/Co-Advisor
Nicholas Alexander Meisel, Thesis Advisor/Co-Advisor - Keywords:
- Additive Manufacturing
Compliant Beams
Design
Finite Element Analysis
ABAQUS
Additive Manufacturing
Compliant Beams
Design
Finite Element Analysis (FEA) - Abstract:
- Additively-manufactured multi-material compliant mechanisms are an emergent class of mechanisms; these mechanisms have a higher reliance on material properties to drive deflection when compared to other compliant mechanisms. As a result, material-specific properties such as Young's modulus, strain response, and Poisson's ratio must be analyzed to properly predict the performance of multi-material additively manufactured compliant mechanisms. This thesis creates a framework for additive manufacturing users to characterize acceptable force-deflection relationship predictors using strain data associated with a generalized multi-material cantilever beam and investigates key variables' responses to key factors such as the difference in Young's Modulus between each material, Poisson's ratio, and applied deflection. This investigation has been compiled into design considerations. Both the framework and design considerations allow designers to have more confidence in the performance of their designs and provide greater insight into what should be altered prior to production. When applied, the framework allows the user to identify the applied deflections where Hooke's Law and small angle assumptions are, or are not, appropriate. The design considerations rank the priority of factors that should be changed based on the designer's ranked importance of responses. This process will be useful for multi-material additive manufacturing processes capable of producing multi-material prints: directed energy deposition (metals) and material extrusion (thermoplastics). This process will serve as the basis for encouraging the widespread adoption of additively manufactured multi-material compliant mechanisms.