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Finite element modelling of defects in additively manufactured strut-based lattice structures

Echeta, Ifeanyichukwu; Dutton, Ben; Leach, Richard K.; Piano, Samanta

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Authors

Ifeanyichukwu Echeta

Ben Dutton



Abstract

Strut-based lattice structures produced by powder bed fusion are prone to characteristic manufacturing defects that alter both their form and surface texture. Most studies in the literature focus on a subset of commonly observed defects, typically radius variation and strut waviness; surface defects remain relatively unexplored. Furthermore, there remains a need for the development of a general finite element modelling framework that can implement a range of defects into any strut-based lattice design. This paper presents a modelling framework for implementing a range of both form and surface defects into finite element meshes of strut-based lattices. A signed distance function forms the foundation for this framework, upon which surface meshes can be modified and converted into tetrahedral meshes via open-source software. The paper demonstrates how radius variation, strut waviness, elliptical cross sections and surface defects can be modelled in lattice struts, for which intuitive mathematical definitions are provided. A parametric study is performed to assess the sensitivity of the compressive Young's modulus of BCCZ and octet-truss lattices to upskin and downskin surface defects. The results showed higher sensitivity in the octet-truss than in the BCCZ; both designs were more sensitive to downskin defects than upskin defects.

Citation

Echeta, I., Dutton, B., Leach, R. K., & Piano, S. (2021). Finite element modelling of defects in additively manufactured strut-based lattice structures. Additive Manufacturing, 47, Article 102301. https://doi.org/10.1016/j.addma.2021.102301

Journal Article Type Article
Acceptance Date Sep 7, 2021
Online Publication Date Sep 20, 2021
Publication Date Nov 1, 2021
Deposit Date Sep 16, 2021
Publicly Available Date Sep 21, 2022
Journal Additive Manufacturing
Print ISSN 2214-7810
Electronic ISSN 2214-8604
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 47
Article Number 102301
DOI https://doi.org/10.1016/j.addma.2021.102301
Keywords Industrial and Manufacturing Engineering; Engineering (miscellaneous); General Materials Science; Biomedical Engineering
Public URL https://nottingham-repository.worktribe.com/output/6242974
Publisher URL https://www.sciencedirect.com/science/article/pii/S2214860421004607

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