Date of Award
5-2025
Document Type
Thesis
Degree Name
Master of Science (MS)
Department
Aerospace, Physics, and Space Sciences
First Advisor
Dr. Mirmilad Mirsayar
Second Advisor
Dr. Ratneshwar Jha
Third Advisor
Dr. Soheil Saedi
Abstract
This study presents a comprehensive investigation into the fracture behavior of additively manufactured orthotropic V-notched components made of Acrylonitrile Butadiene Styrene (ABS) material. The research integrates both theoretical and finite element approaches to evaluate stress intensity factors (SIFs) in Modes-I and II, which are fundamental in characterizing stress field distributions around notches under applied loading conditions. Unlike isotropic materials, where stress fields depend only on geometry of the component, the anisotropic nature of 3D-printed ABS introduces a dependency on material properties that necessitate different approaches to include anisotropy of the material.
Tensile specimens are 3D-printed with specific material orientations to find material properties. Tensile and shear tests are conducted using a Universal Testing Machine (UTM) equipped with Digital Image Correlation (DIC) for precise stress and strain measurement. The determined material properties were then used in calculating the eigenvalues, derived from a characteristic equation dependent on material properties, notch opening angles, and geometric parameters. Once the eigenvalues are determined, SIFs for both mode-I and mode-II are determined and integrated into stress field equations to predict fracture behavior around the notch tips. These theoretical predictions of stress fields were validated through Finite Element Analysis (FEA) simulations, which model the stress distributions around the notch tip with varying print orientations.
Fracture specimen are 3D-printed using ABS and were tested on a tensile tester to determine the fracture load. The obtained fracture load is used to calculate SIFs at the onset of fracture through normalized FE simulations. This study highlights the importance of material orientation in influencing fracture modes, with Mode I and Mode II dominance shifting based on material orientation. The findings of this research contribute valuable insights into the fracture mechanics of 3D-printed materials that usually exhibit orthotropic behavior due to print orientation, offering a deeper understanding of stress distributions in notched structures. The results emphasize the crucial role of material properties in understanding fracture behavior in an anisotropic environment, making this study highly relevant to aerospace, automotive, and structural engineering applications where customized 3D-printed components are increasingly utilized.
Recommended Citation
Bavapuram, Venkata Siva Sainath, "Experimental and Theoretical Fracture Analysis of Additively Manufactured Orthotropic V-Notches" (2025). Theses and Dissertations. 1535.
https://repository.fit.edu/etd/1535
Included in
Computer-Aided Engineering and Design Commons, Engineering Mechanics Commons, Manufacturing Commons, Mechanics of Materials Commons, Structures and Materials Commons
