The design of modern mechanical components often requires the use of low-density and high-strength parts. Additive manufacturing presents competence in obtaining format complexity internally (voids, ducts, channels) and externally (shape, holes). However, parts obtained by material extrusion additive manufacturing are highly anisotropic and relatively weak. This paper aims to present a new mechanical design technique that combines the high geometry flexibility of additive manufacturing with internal structuring reinforcement by high-strength materials, which enables optimized parts with reinforcement in the most mechanical stressed areas during service, through adopting structured internal geometry filled with reinforcement material. Dense test specimens and test specimens with internal structural canals filled with reinforcement material (epoxy resin and carbon fibers) were designed, fabricated and tested physically and virtually. The obtained results provide property values for 3D-printed acrylonitrile butadiene styrene (typical material of additive manufacturing) and for this polymer reinforced with various reinforcement material configurations (useful for mechanical design). The reinforcement decreased anisotropy and improved mechanical properties. Optimized parts filled with resin and long carbon fibers had maximum flexural resistance of 112 MPa, with a specific weight of 1.1 g/cm3. This reinforcement provided parts with specific flexural strength similar to structural aluminum alloys, preserving the geometry and external dimension of the printed parts. The technique presented here shows the possibility of new conceptions in mechanical components design and strength optimization by internal reinforcement canals in parts. The technique is useful for mechanical design activity and allows for new product conceptions based on additive manufacturing.

中文翻译：

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基于增材制造和内部加固的机械结构设计

现代机械部件的设计往往需要使用低密度和高强度的零件。增材制造在获得内部（空隙、管道、通道）和外部（形状、孔）格式复杂性方面表现出能力。然而，通过材料挤压增材制造获得的零件具有高度各向异性且相对较弱。本文旨在提出一种新的机械设计技术，将增材制造的高几何灵活性与高强度材料的内部结构加固相结合，通过采用结构化的内部几何填充，使优化的零件在服役期间机械应力最大的区域得到加固。带增强材料。密集的测试样本和内部结构管道填充有增强材料（环氧树脂和碳纤维）的测试样本被设计、制造和物理和虚拟测试。获得的结果提供了 3D 打印的丙烯腈丁二烯苯乙烯（增材制造的典型材料）和这种用各种增强材料配置增强的聚合物（用于机械设计）的属性值。增强材料降低了各向异性并提高了机械性能。填充树脂和长碳纤维的优化部件的最大抗弯强度为 112 MPa，比重为 1.1 g/cm3。这种增强为零件提供了类似于结构铝合金的特定抗弯强度，保留了打印零件的几何形状和外部尺寸。此处介绍的技术显示了通过零件中的内部增强管在机械部件设计和强度优化方面的新概念的可能性。该技术可用于机械设计活动，并允许基于增材制造的新产品概念。