Influence of residual stress and fluid–structure interaction on the impact behavior of fused filament fabrication components

Despite the proliferation of cellular fused filament fabrication (FFF) polymer components for a variety industrial applications, few studies have investigated their fluid–structure interaction (FSI) behavior during loading, particularly under dynamic impact conditions. Furthermore, extent to which residual stresses from FFF build process affect load bearing characteristics has not been addressed. In this work, simulations and experiments are conducted cylindrical nylon specimens fabricated with two different internal closed-cell cavity structures assess influence entrapped fluid on state stress high strain-rate impact. The demonstrated 2-stage computational approach includes thermomechanical model calculate distortion, forms initial subsequently executed using smoothed particle hydrodynamics (SPH) capture effects air within cavities. Dynamic displacement boundary conditions FSI identified digital image correlation (DIC), obtained performed split Hopkinson pressure bar (SHPB) tests. Findings reveal that significantly stress–strain response impact, even at strain rates 500–600 s−1. addition, while influences both vary structure, study reveals coupled must be considered accurately characterize behavior. Validity numerical approach, as well significance FSI, justified by comparing predictions experimental measurements, observing root-mean-square errors 12.77% 11.87%, peak 1.93% 1.34% specimens.