Vibration Fatigue of FDM 3D Printed Structures: The Use of Frequency Domain Approach

Damping Optimization and Energy Absorption of Mechanical Metamaterials for Enhanced Vibration Control Applications: A Critical Review

Metamaterials are pushing the limits of traditional materials and are fascinating frontiers in scientific innovation. Mechanical metamaterials (MMs) are a category of metamaterials that display properties and performances that cannot be realized in conventional materials. Exploring the mechanical properties and various aspects of vibration and damping control is becoming a crucial research area. Their geometries have intricate features inspired by nature, which make them challenging to model and fabricate. The fabrication of MMs has become possible because of the emergence of additive manufacturing (AM) technology. Mechanical vibrations in engineering applications are common and depend on inertia, stiffness, damping, and external excitation. Vibration and damping control are important aspects of MM in vibrational environments and need to be enhanced and explored. This comprehensive review covers different vibration and damping control aspects of MMs fabricated using polymers and other engineering materials. Different morphological configurations of MMs are critically reviewed, covering crucial vibration aspects, including bandgap formation, energy absorption, and damping control to suppress, attenuate, isolate, and absorb vibrations. Bandgap formation using different MM configurations is presented and reviewed. Furthermore, studies on the energy dissipation and absorption of MMs are briefly discussed. In addition, the vibration damping of various lattice structures is reviewed along with their analytical modeling and experimental measurements. Finally, possible research gaps are highlighted, and a general systematic procedure to address these areas is suggested for future research. This review paper may lay a foundation for young researchers intending to start and pursue research on additive-manufactured MM lattice structures for vibration control applications.

Frequency-Dependent Fatigue Properties of Additively Manufactured PLA

Vibration-fatigue failure occurs when a structure is dynamically excited within its natural frequency range. Unlike metals, which have constant fatigue parameters, polymers can exhibit frequency-dependent fatigue parameters, significantly affecting the vibration resilience of 3D-printed polymer structures. This manuscript presents a study utilizing a novel vibration-fatigue testing methodology to characterize the frequency dependence of polymer material fatigue parameters under constant temperature conditions. In this investigation, 3D-printed PLA samples with frequency-tunable geometry were experimentally tested on an electro-dynamical shaker with a random vibration profile. Using the validated numerical models, the estimation of vibration-fatigue life was obtained and compared to the experimental results. Performing the numerical minimization of estimated and actual fatigue lives, the frequency-dependent fatigue parameters were assessed. In particular, the results indicate that the tested samples exhibit varying fatigue parameters within the loading frequency range of 250-750 Hz. Specifically, as the loading frequency increases, the fatigue exponent increases and fatigue strength decreases. These findings confirm the frequency dependence of fatigue parameters for 3D-printed polymer structures, underscoring the necessity of experimental characterization to reliably estimate the vibration-fatigue life of 3D-printed polymer structures. The utilization of the introduced approach therefore enhances the vibration resilience of the 3D-printed polymer mechanical component.

Influence of 3D Printing Direction in PLA Acoustic Guitars on Vibration Response

The design of musical instruments is a discipline that is still carried out in an artisanal way, with limitations and high costs. With the additive manufacturing technique, it is possible to obtain results for the generation of not only electrical but also acoustic instruments. However, it is necessary to generate a procedure to evaluate the influence of the process on the final result of the acoustics obtained. This study focuses on investigating the relationship between the construction of acoustic guitars and their final sound. The reinforcement structures at the top of the instrument are analysed, as well as how this design affects the vibratory behaviour of the top in the first five vibratory modes. Specifically, this article presents a procedure for the design of customised acoustic guitars using additive manufacturing through parametrisation and a vibrational analysis of the designed tops using finite element (FEA) and experimental physical tests, in order to develop a methodology for the study of stringed instruments. As a result, an 11% increase in the high-frequency response was achieved with a printing direction of +45°, and a reduction in the high-frequency response with ±45°. In addition, at high frequencies, a relative error of 5% was achieved with respect to the simulation. This work fulfils an identified need to study the manufacture of acoustic guitars using polylactic acid (PLA), and to be able to offer the musician a customised instrument. This represents a breakthrough in the use of this manufacturing technology, extending its relationship with product design.

Development and Validation of a Low-Cost Device for Real-Time Detection of Fatigue Damage of Structures Subjected to Vibrations

This paper presents the development and validation of a low-cost device for real-time detection of fatigue damage of structures subjected to vibrations. The device consists of an hardware and signal processing algorithm to detect and monitor variations in the structural response due to damage accumulation. The effectiveness of the device is demonstrated through experimental validation on a simple Y-shaped specimen subjected to fatigue loading. The results show that the device can accurately detect structural damage and provide real-time feedback on the health status of the structure. The low-cost and easy-to-implement nature of the device makes it promising for use in structural health monitoring applications in various industrial sectors.

Numerical and Experimental Study of the Fatigue Behavior for a Medical Rehabilitation Exoskeleton Device Using the Resonance Method

In this paper, the dynamic behavior of a hip level joint device of an active exoskeleton used in the medical field is analyzed. The finite element method is used in order to determine the first frequencies and the eigenmodes, necessary for the fatigue testing in the resonance regime.

Towards Highly Efficient, Additively Manufactured Passive Vibration Eliminators for Mechanical Systems

Structural damping largely determines the dynamic properties of mechanical structures, especially those whose functioning is accompanied by time-varying loads. These loads may cause vibrations of a different nature, which adversely affects the functionality of the structure. Therefore, many studies have been carried out on vibration reduction methods over the last few years. Among them, the passive vibration damping method, wherein a suitable polymer system with appropriate viscoelastic properties is used, emerges as one of the simplest and most effective methods. In this view, a novel approach to conduct passive elimination of vibrations, consisting of covering elements of structures with low dynamic stiffness with polymeric pads, was developed. Herein, polymer covers were manufactured via fused filament fabrication technology (3D printing) and were joined to the structure by means of a press connection. Current work was focused on determining the damping properties of chosen polymeric materials, including thermoplastic elastomers (TPE). All investigated materials were characterized by means of differential scanning calorimetry (DSC), dynamic mechanical thermal analysis (DMTA), and mechanical properties (tensile test and Shore hardness). Lastly, the damping ability of pads made from different types of polymers were evaluated by means of dynamic tests.

Filament Transport Control for Enhancing Mechanical Properties of Parts Realised by Fused Filament Fabrication

The fused filament fabrication (FFF) process is widely used for producing prototypes and functional parts for diverse applications. While FFF is particularly attractive due to its cost-effectiveness, on the other hand, the fabricated parts have limitations in terms of large manufacturing time and reduced mechanical properties. The latter is strongly influenced by the fabrication process parameters, which affect the interlayer bonding and the adhesion between consecutive layers. Several works presented in the literature analysed the correlation between mechanical properties and process parameters. It was demonstrated that an increase in the fabrication feed rate causes slippage between filament and the feeding system, which leads to a decrease in the extruded material flow, and thus in part density. This work aims to investigate how the limitation of the slippage phenomenon affects the mechanical properties of parts fabricated using the FFF process. A prototype machine, equipped with a closed-loop control system on filament transport, was used to fabricate samples for tensile tests and dynamical mechanical analysis. Samples fabricated enabling the filament transport control showed an increase both in ultimate tensile strength and elongation at break for those fabricated with disabled control, whilst a decrease in stiffness was observed. In addition, the results showed that the use of a filament transport control system on a FFF machine increases the possibility of fabricating high value-added parts.