Residual stress and warpage of additively manufactured SCF/PLA composite parts

With the rapid development of novel technologies, additive manufacturing of carbon fiber-reinforced composites is drawing increasing attention in various industrial applications. In this study, we develop numerical models to predict and analyze the stress distribution, crystallinity and warpage mechanisms of two commonly used structural parts, i.e., a square tube (ST) and a circular tube (CT), made of short carbon fiber-reinforced polylactic acid (SCF/PLA) with additive manufacturing using fused filament fabrication (FFF). First, a multi-physics field model considering thermoelastic relations and crystallization kinetics was developed to simulate the FFF printing process using numerical "activated elements." Then, the most important numerical parameters were experimentally evaluated to refine the numerical model for prediction and analysis. The results show that the composite ST specimens have a significant residual stress distribution and are prone to stress concentrations at the edges and corners. Specifically, the maximum warpage value, i.e., at the corner of ST specimens (100.47 mu m), is higher than that of CT specimens (88.45 mu m). Overall, the difference in crystallinity for additively manufactured composite tubes with different configurations is small (average crystallinities of ST and CT specimens are 5.22% and 6.1%, respectively). However, the crystallinity tends to generally decrease along the tube height direction, from the bottom upwards to the upper area beneath the printing nozzle.