Multiscale Simulation of Semi-Crystalline Polymers to Predict Mechanical Properties.

A multiscale simulation method for the determination of mechanical properties of semi-crystalline polymers is presented. First, a four-phase model of crystallization of semi-crystalline polymers is introduced, which is based on the crystallization model of Strobl. From this, a simulation on the nanoscale is derived, which models the formation of lamellae and spherulites during the cooling of the polymer by using a cellular automaton. In the solidified state, mechanical properties are assigned to the formed phases and thus the mechanical behavior of the nanoscale is determined by a finite element (FE) simulation. At this scale, simulations can only be performed up to a simulation range of a few square micrometers. Therefore, the dependence of the mechanical properties on the degree of crystallization is determined by means of homogenization. At the microscale, the cooling of the polymer is simulated by a cellular automaton according to evolution equations. In combination with the mechanical properties determined by homogenization, the mechanical behavior of a macroscopic component can be predicted.

Media for Dimensional Stabilization of Rubber Compounds during Additive Manufacturing and Vulcanization.

The current article proposes a concept for the additive manufacturing of rubber components using extrusion-based 3D printing, in which an additional medium is added to ensure the maintenance of shape within the elastomeric structure during the additive manufacturing process and in the subsequent vulcanization process. Specific requirements for the dimensional stabilization of the media were defined and suitable media were derived. Silicone rubber, molding sand, and plaster were examined in experimental vulcanization tests for their suitability as possible media with regard to shape retention. Selected rubber geometries made of NBR were embedded in these media to undergo the vulcanization process. The results show a significant influence of the media on the heating times. All media were able to ensure that the rubber geometries maintained their shape during vulcanization. Nevertheless, some side effects were found. The silicone rubber did not cure properly around the rubber sample. Therefore, it was difficult to remove it from the rubber after vulcanization. The molding sand caused an increased surface roughness on the rubber. Plaster changed the glossy surfaces at the beginning to a matte one after vulcanization and residuals were difficult to remove. However, all media can serve as stabilization media with specific changes.

Basic Research for Additive Manufacturing of Rubber.

The dissemination and use of additive processes are growing rapidly. Nevertheless, for the material class of elastomers made of vulcanizable rubber, there is still no technical solution for producing them using 3D printing. Therefore, this paper deals with the basic investigations to develop an approach for rubber printing. For this purpose, a fused deposition modeling (FDM) 3D printer is modified with a screw extruder. Tests are carried out to identify the optimal printing parameters. Afterwards, test prints are performed for the deposition of rubber strands on top of each other and for the fabrication of simple two-dimensional geometries. The material behavior during printing, the printing quality as well as occurrences of deviations in the geometries are evaluated. The results show that the realization of 3D rubber printing is possible. However, there is still a need for research to stabilize the layers during the printing process. Additionally, further studies are necessary to determine the optimum parameters for traverse speed and material discharge, especially on contours.