Effect of additive manufactured hybrid and functionally graded novel designed cellular lattice structures on mechanical and failure properties

Sajjad Hussain, Aamer Nazir*, Saad Waqar, Usman Ali, Ozkan Gokcekaya

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

5 Scopus citations

Abstract

Recent advancements in additive manufacturing (AM) have opened new possibilities for fabricating highly complex lattice structures with enhanced mechanical properties, particularly hybrid and functional gradient structures. Most of the conducted research focused on linear/longitudinal designs for both hybrid and functional gradient structures. This study focuses on designing and evaluating novel functionally graded radially hybridized structures, combining different unit cells from beam-based and surface-based structures. The research introduces a cylindrical/radial hybridization approach, incorporating three distinct unit cells: body-centered cubic (BCC), face-centered cubic (FCC), and octet from beam-based structures, and diamond, gyroid, and split-p from surface-based structures. Polylactic acid (PLA) was selected as the material, and fused filament fabrication (FFF) was employed for fabrication. Quasi-static compression tests were conducted to assess the influence of hybridization and functional gradience on compressive modulus, ultimate strength, specific energy absorption, and failure properties. Both experimental and numerical results demonstrated that functionally graded lattice structures, whether surface-based or beam-based, exhibited improved mechanical performance. The surface-based functionally graded lattice structures showed the highest compressive modulus (71%), ultimate strength (36%), and specific energy absorption (19%). On the other hand, the beam-based functionally graded structures displayed a higher compressive modulus (50%), ultimate strength (11%), and specific energy absorption (19%). However, it should be noted that the beam-based functionally graded structures exhibited a decrease in these properties due to factors such as unit cell size, volume fraction, and structural buckling. Overall, the findings highlight the superior mechanical properties of functionally graded lattice structures compared to hybrid lattice structures.

Original languageEnglish
Pages (from-to)4873-4891
Number of pages19
JournalInternational Journal of Advanced Manufacturing Technology
Volume128
Issue number11-12
DOIs
StatePublished - Oct 2023

Bibliographical note

Publisher Copyright:
© 2023, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.

Keywords

  • Additive manufacturing
  • Buckling
  • Cylindrical/radial design
  • Deformation
  • Energy absorption
  • Functionally graded
  • Hybrid lattice structures

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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