Session: 03-08-02: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 113259

113259 - Computational Analysis of the Compressive Behavior of TPMS Graded Lattice Structures Versus Primitive TPM Lattice Structures Produced by Additive Manufacturing 

Additive manufacturing (AM) can be used to fabricate complex geometries such as lattice structures, which have tailored mechanical, thermal, and fluid-dynamic properties that are difficult to produce using traditional subtractive methods such as computer numerical control (CNC) machining. Applications of AM lattice structures have been found in the light-weighting of automotive and aerostructures, sandwich cores, energy absorption and blast protection. The design freedom afforded by AM allows for the production of parts with virtually limitless complexity, including periodic lattice structures that fill volumes bounded by complex surface geometry. The accurate prediction of the mechanical behavior of lattice-structured parts manufactured using AM is crucial to ensure that they meet their design criteria, such as stiffness and adequate strength to avoid failure. Analytical approaches, such as traditional force methods and Maxwell's Stability Criterion, can be used, but these methods have limited predictive capabilities.

Triply periodic minimal surfaces (TPMS) are widely used as the basis for designing lattice structures due to their unique geometric properties. Recent studies have shown that graded TPMS lattice structures can enhance their mechanical properties by tailoring their properties across the structure. However, there is still a lack of understanding of how the graded structure affects their compressive behavior. This study aims at comparing the compressive behavior of TPMS-graded lattice structures and primitive TPMS lattice structures produced by additive manufacturing. Finite element analysis is used to capture the effect of the graded lattice structure on the mechanical behavior. A MATLAB® code is used to create TPMS lattice structures (Diamond structure) in STL (stereolithography) format, which were then imported into Fusion360® for further analysis and optimization. This allowed for the development of design guidelines for TPMS lattice structures using additive manufacturing techniques. This conversion is necessary in order to perform mechanical analysis and optimization of the lattice structure using computational modeling tools. The solid mesh representation allows for more accurate simulations of the behavior of the lattice structure, including its strength, stiffness, and other mechanical properties. This is an essential step in the design and optimization of TPMS lattice structures using additive manufacturing techniques. The FE model is validated using published experimental results and is used to compare the compressive behavior of the two lattice structures. The effect of graded lattice structure on the performance is also analyzed. The FE model incorporates graded porosity distribution to capture the effect of the graded lattice structure. The results provide valuable insights into the compressive behavior of TPMS-graded lattice structures and contribute to improved design and optimization techniques for additive-manufactured lattice structures.

Presenting Author: Khaled Al-Athel King Fahd University of Petroleum & Minerals

Presenting Author Biography: Dr. Al-Athel got his BS and MS from King Fahd University of Petroleum & Minerals in Mechanical Engineering in 2002 and 2005, respectively. He got his PhD form the University of British Columbia in 2010. Dr. Al-Athel worked as a post-doc at MIT in 2012-2013. He is currently an Associate Professor in the Mechanical Engineering department at King Fahd University of Petroleum & Minerals and holds the position of Dean of College of Engineering & Physics.

Authors:

Ahmed Abdelaal King Fahd University of Petroleum & Minerals
Khaled Al-Athel King Fahd University of Petroleum & Minerals
Abba Abubakar King Fahd University of Petroleum & Minerals
Usman Ali King Fahd University of Petroleum & Minerals
Syed Sohail Akhtar King Fahd University of Petroleum & Minerals