Embedding sensors within additive manufactured (AM) structures gives the ability to develop smart structures that are capable of monitoring the mechanical health of a system. AM provides an opportunity to embed sensors within a structure during the manufacturing process. One major limitation of AM technology is the ability to verify the geometric and material properties of fabricated structures. Over the past several years, the electromechanical impedance (EMI) method for structural health monitoring (SHM) has been proven to be an effective method for sensing damage in structurers. The EMI method utilizes the coupling between the electrical and mechanical properties of a piezoelectric transducer to detect a change in the dynamic response of a structure. A piezoelectric device, usually a lead zirconate titanate (PZT) ceramic wafer, is bonded to a structure and the electrical impedance is measured across as range of frequencies. A change in the electrical impedance is directly correlated to changes made to the mechanical condition of the structure. In this work, the EMI method is employed on piezoelectric transducers embedded inside AM parts to evaluate the feasibility of performing SHM on parts fabricated using additive manufacturing. The fused deposition modeling (FDM) method is used to print specimens for this feasibility study. The specimens are printed from polylactic acid (PLA) in the shape of a beam with an embedded monolithic piezoelectric ceramic disc. The specimen is mounted as a cantilever while impedance measurements are taken using an HP 4194A impedance analyzer. Both destructive and nondestructive damage is simulated in the specimens by adding an end mass and drilling a hole near the free end of the cantilever, respectively. The Root Mean Square Deviation (RMSD) method is utilized as a metric for quantifying damage to the system. In an effort to determine a threshold for RMSD, the values are calculated for the variation associated with taking multiple measurements and with re-clamping the cantilever, and determined to be 0.154, and 3.125 respectively. The RMSD value of the cantilever with a 400 g end mass is 11.39, and the RMSD value of the cantilever with a 4 mm hole near the end is 12.15. From these results, it can be determined that the damaged cases have much higher RMSD values than the RMSD values associated with measurements and set up variability of the healthy structure.
The evolution of additive manufacturing has allowed engineers to use 3D printing for many purposes. As a natural consequence of the 3D printing process, the printed object is anisotropic. As part of an ongoing project to embed piezoelectric devices in 3D printed structures for structural health monitoring (SHM), this study aims to find the mechanical properties of the 3D printed material and the influence of different external factors on those properties. The orthotropic mechanical properties of a 3D printed structure are dependent on the printing parameters used to create the structure. In order to develop an orthotropic material model, mechanical properties will be found experimentally from additively manufactured samples created from polylactic acid (PLA) using a consumer-level fused deposition modeling (FDM) printer; the Lulzbot TAZ 6. Nine mechanical constants including three Young's moduli, three Poisson’s ratios, and three shear moduli are needed to fully describe the 3D elastic behavior of the material. Printed specimens with different raster orientations and print orientations allow calculation of the different material constants. In this work, seven of the nine mechanical constants were found. Two shear moduli were unable to be measured due to difficulties in printing two of the sample orientations. These mechanical properties are needed in order to develop orthotropic material models of systems employing 3D printed PLA. The results from this paper will be used to create a model of a piezoelectric transducer embedded in a 3D printed structure for structural health monitoring.
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