ABSTRACT
Additive manufacturing is an emerging technology and provides high design flexibility to customers. Fused deposition modeling (FDM) is an economical and promising additive manufacturing method. Due to its many advantages, FDM received great attention in recent years, and comprehensive studies are being undertaken to investigate the properties of FDM-printed polymers and polymer composites. As a result of the manufacturing technology employed in FDM, inner structures are changed with different process parameters, and thus, anisotropic properties are observed. Moreover, composite filaments such as particle- or fiber-reinforced polymers already have anisotropy before FDM printing. In this study, we investigate the effect of different process parameters, namely layer thickness and raster width on FDM-printed copper-reinforced poly(lactic acid) (PLA). Mechanical characterizations with a high-resolution camera are carried out for analyzing the deformation behaviors. Optical microscopy characterizations are performed to observe the mesostructural changes with various process parameters. Scanning electron microscopy (SEM) and an energy-dispersive X-ray spectroscopy (EDS) analysis are conducted for investigating the microstructure, specifically, copper particles in the PLA matrix. A 2D digital image correlation code with a machine learning algorithm is applied to the optical characterization and SEM-EDS images. In this way, micro- and mesostructural features, as well as the porosity ratios of the specimens are investigated. We prepare the multiscale homogenization by finite element method (FEM) simulations to capture the material's response, both on a microscale and a mesoscale. We determined that the mesostructure and, thereby, the mechanical properties are significantly changed with the aforementioned process parameters. A lower layer thickness and a greater raster width led to a higher elasticity modulus and ultimate tensile strength (UTS). The optical microscopy analysis verified this statement: Decreasing the layer thickness and increasing the raster width result in larger contact lines between adjacent layers and, hence, lower porosity on the mesoscale. Realistic CAD images were prepared regarding the mesostructural differences and porosity ratios. Ultimately, all these changes are accurately modeled with mesoscale and multiscale simulations. The simulation results are validated by laboratory experiments.
ABSTRACT
Teeth with intact crowns rarely split or fracture, despite decades of cyclic loading and occasional unexpected overload. This is largely attributed to the presence of dentine, since cracking and fracture of enamel have been frequently reported. Dentine is similar to bone, comprising mineralised collagen fibres as a main constituent. Unlike cortical bone, however, where microcracking and damage arrest are essential for re/modelling and healing, dentine can neither remodel nor regenerate. This raises questions regarding the evolutionary benefits of toughening, leading to uncertainty whether cracks actually appear in dentine in situ. Here we study the notion that circumpulpal dentine is usually protected against, rather than damaged by severe overloads, even though it is not much more massive or stronger than it needs to be. To address this, we examined hydrated teeth still within whole jawbones of freshly-slaughtered skeletally mature pigs, mechanically loaded until fracture. Force displacement curves, optical and electron microscopy combined with 3D microstructural analysis by conventional micro-computed tomography (µCT) revealed mostly brittle fracture paths in circumpulpal crown dentine. Once overload cracks reach this mass of dentine they propagate rapidly along straight paths often parallel to the enamel flanks of the oblong shovel shaped premolars. We find infrequent signs of active toughening mechanisms with minimal crack diversion, ligament bridging and microcracking. When such toughening is seen, it mainly appears in softer dentine in the root, or near the dentine-enamel-junction (DEJ) in mantle dentine. We observed shear bands in overloaded circumpulpal dentine, due to mutual gliding of upper and lower segments. These shear bands are formed as periodic arrays of rotated dentine fragments. The 3D data consistently demonstrate the importance of the layered tooth structure, containing a stiff outer enamel shell, a soft sub-DEJ interlayer and a stiff circumpulpal dentine bulk, for deflecting cracks from splitting the tooth.
