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RELFIT: A program for determining prony series fits to measured relaxation data

Description: Viscoelastic materials are often characterized in terms of stress relaxation moduli which decay in time. Finite element programs which model viscoelastic materials frequently require that these relaxation functions be defined as an exponential series (i.e., Prony Series) to exploit the numerical advantages of developing recursive equations for evaluating hereditary integrals. Obtaining these data fits can be extremely difficult when the data is spread over many decades in the logarithm of time. RELFIT is a nonlinear optimization program that iteratively determines the Prony series coefficients and relaxation times so as to minimize the least squares error in the data fit. An overview of the code, a description of the required inputs (i.e., users`s instructions), and a demonstration problem are presented.
Date: April 1, 1997
Creator: Chambers, R.S.
Partner: UNT Libraries Government Documents Department

Coupled thermal/structural analyses of laser powered glass sealing methods for fiber optic and flat panel display applications

Description: Glasses are used extensively by the electronics industry for packaging and in components. Because glasses have such low fracture toughness, glass components must maintain low tensile stresses to avoid cracking and ensure product stability. Modeling is a key tool for developing designs with low tensile stresses. Thermoelastic analyses are ideal for modeling slow, oven controlled processes where the temperature varies uniformly. Many processing environments, however, involve rapid heating and cooling cycles that produce nonhomogeneous temperature fields causing the volume and stresses in the glass to relax at different rates. This structural relaxation is an important nonlinear material behavior that gives rise to a point-to-point variability in effective properties of the material. To accurately model such stresses, a thermal analysis must be coupled to a structural analysis that employs a viscoelastic model of glass. Laser sealing of glasses is an example of a process where thermal history is an important factor in determining the residual stress state. Recent needs to consider laser sealing methods for fiber optic connectors and flat panel displays have spurred the development of coupled, three-dimensional thermal and structural finite element codes. Analyses of the temperatures and stresses generated in a flat panel display during a laser sealing operation are presented, an the idiosyncrasies and importance of modeling coupled thermal/structural phenomena are discussed.
Date: December 31, 1996
Creator: Chambers, R.S. & Gianoulakis, S.E.
Partner: UNT Libraries Government Documents Department

In-situ property measurements on laser-drawn strands of SL 5170 epoxy and SL 5149 acrylate

Description: Material behavior plays a significant role in the mechanics leading to internal stresses and, potentially, to distortion (curling) of parts as they are built by stereolithography processes that utilize photocuring resins. A study is underway to generate material properties that can be used to develop phenomenological material models of epoxy and acrylate resins. Strand tests are performed in situ in a 3D System`s SLA-250 machine; strands are drawn by either single or multiple exposures of the resin to a laser beam. Linear shrinkage, cross-sectional areas, cure shrinkage forces and stress-strain data are presented. Also, the curl in cantilever beam specimens, built with different draw patterns, are compared.
Date: August 1, 1995
Creator: Guess, T.R. & Chambers, R.S.
Partner: UNT Libraries Government Documents Department

A phenomenological finite element model of stereolithography processing

Description: In the stereolithography process, three dimensional parts are built layer by layer using a laser to selectively cure slices of a photocurable resin, one on top of another. As the laser spot passes over the surface of the resin, the ensuing chemical reaction causes the resin to shrink and stiffen during solidification. When laser paths cross or when new layers are cured on top of existing layers, residual stresses are generated as the cure shrinkage of the freshly gelled resin is constrained by the adjoining previously-cured material. These internal stresses can cause curling in the compliant material. A capability for performing finite element analyses of the stereolithography process has been developed. Although no attempt has been made to incorporate all the physics of the process, a numerical platform suitable for such development has been established. A methodology and code architecture have been structured to allow finite elements to be birthed (activated) according to a prescribed order mimicking the procedure by which a laser is used to cure and build-up surface layers of resin to construct a three dimensional geometry. In its present form, the finite element code incorporates a simple phenomenological viscoelastic material model of solidification that is based on the shrinkage and relaxation observed following isolated, uncoupled laser exposures. The phenomenological material model has been used to analyze the curl in a simple cantilever beam and to make qualitative distinctions between two contrived build styles.
Date: March 1, 1996
Creator: Chambers, R.S.; Guess, T.R. & Hinnerichs, T.D.
Partner: UNT Libraries Government Documents Department

A phenomenological finite element model of part building in the stereolithography process

Description: The finite element method has been used to develop the framework for a tool that can be used to model the structural deformation arising from the stereolithography build process. Such a tool when fully developed can facilitate numerical studies aimed at evaluating build parameters and build styles. Although the current software makes no attempt to capture all the physics of the process, provisions for three important build features have been made: (1) laser path history including scanning rate and depth of cure, (2) structural linkage, and (3) time varying material behavior. For demonstration purposes, a three dimensional finite element code was modified to include a phenomenological material model of solidification. The model was based on cure shrinkage and stress relaxation data collected from in-situ tests on individual strands drawn using 3D Systems` stereolithography apparatus (SLA-250). To depict the directed path of solidification within layers, a finite element birthing scheme was conceived to activate elements along the predetermined coordinate path of the laser. Structural linkage was enforced by joining element strands of layers when laser paths connect or overlap, respectively. A limited number of analyses have been performed to contrast simple build styles.
Date: March 1, 1995
Creator: Chambers, R.S.; Guess, T.R. & Hinnerichs, T.D.
Partner: UNT Libraries Government Documents Department

Epoxy and acrylate sterolithography resins: in-situ property measurements

Description: Stereolithography is a rapid prototyping method that is becoming an important product realization and concurrent engineering tool, with applications in advanced and agile manufacturing. During the build process, material behavior plays a significant role in the mechanics leading to internal stresses and, potentially, to distortion (curling) of parts. The goal of the ``Stereolithography Manufacturing Process Modeling and Optimization`` LDRD program was to develop engineering tools for improving overall part accuracy during the stereolithography build process. These tools include phenomenological material models of solidifying stereolithography photocurable resins and a 3D finite element architecture that incorporates time varying material behavior, laser path dependence, and structural linkage. This SAND report discusses the in situ measurement of shrinkage and force relaxation behavior of two photocurable resins, and the measurement of curl in simple cantilever beams. These studies directly supported the development of phenomenological material models for solidifying resins and provided experimental curl data to compare to model predictions.
Date: January 1, 1996
Creator: Guess, T.R.; Chambers, R.S. & Hinnerichs, T.D.
Partner: UNT Libraries Government Documents Department

Epoxy and acrylate stereolithography resins: In-situ measurements of cure shrinkage and stress relaxation

Description: Cross-sections of resin strands. Techniques were developed to make in situ measurements of gelled resin to determine linear shrinkage, stress-strain response and stress relaxation of single strands of SL 5170 epoxy and SL 5149 photocurable resins. Epoxy strands shrank approximately 1.4% and the acrylate strands about 1.0% after a single exposure. No forces were measured during cure shrinkage of strands following the first laser exposure. In multiple laser exposures, the acrylate continues to shrink; whereas (University of Dayton data) no additional shrinkage is observed in epoxy strands on a second hit. In force relaxation tests, a strand is drawn and then a 0.5% step strain is applied after different elapsed times. The epoxy initial modulus evolves (increases) with elapsed time following draw of the strand, and this evolution in modulus occurs after linear shrinkage has stopped. On the other hand, acrylates show no evolution of modulus with elapsed time following a single laser draw; i.e., once shrinkage stops after one laser hit, the initial modulus remains stable with elapsed time. Finally, relaxation response times of epoxy strands get larger with increasing elapsed time after laser draw. In acrylate strands there was no evolution in initial modulus with elapsed time after a single draw so relaxation times are not a function of elapsed time after a single hit with the laser.
Date: March 1, 1995
Creator: Guess, T.R.; Chambers, R.S.; Hinnerichs, T.D.; McCarty, G.D. & Shagam, R.N.
Partner: UNT Libraries Government Documents Department