Experimental characterization and finite element simulation of FDM 3D printed polymer composite tooling for sheet metal stamping

3D printed polymer composite materials offer a cost-effective and rapid tooling option for prototyping, and low-cost, low-volume sheet metal forming applications. Due to the high anisotropy in mechanical properties of 3D printed composites, accurate characterization and finite element modeling of the material become paramount for successful design and application of these forming tools. This paper presents experimental characterization of 3D printed fiber-reinforced polymer composite material at various strain rates. A homogenized material model with orthotropic elasticity and the Hill 1948 anisotropic yield criterion were then calibrated based on these experimental data. Finite element simulations of the stamping of high-strength steel sheets using composite tooling were performed, and tool deformation was predicted and compared with experimental measurements. FE simulation results were in good agreement with stamping experiments performed with polymer tooling. It was found that the anisotropy and strain rate sensitivity of 3D printed polymer composites play a significant role in their performance as tooling materials.

Automated summary

This paper investigates the mechanical properties of 3D printed fiber-reinforced polymer composite materials. Through experimental characterization and finite element modeling, the effectiveness of this material as a forming tool is demonstrated, and the significant influence of anisotropy and strain rate sensitivity on its performance is discovered.