Modeling and optimization of mechanical characteristics of additively manufactured ABS sandwich structure by using response surface methodology

Despite the great technological advances in drones systems, their airframes still need to bolster their materials, geometries and structures to face requirements of resistance and lightness. The aim of this work is to study the influence of geometric parameters on the mechanical properties of additively manufactured ABS sandwich structure by using response surface methodology. It focuses on evaluating the characteristics and influences of geometric parameters as a function of cell width (6, 8 and 10 mm), cell thickness (1, 2 and 3mm) and cell angle (115,130 and 145 degree) on performance factors of elasticity modulus, cell lightness and Poisson coefficient of ABS sandwich structure. The experiment design was carried out using the analysis of variance (ANOVA) according to L27 orthogonal array. Specimens of ABS sandwich structure are obtained by additive manufacturing process on which mechanical tests then were performed to confirm numerical results. The findings indicate a stronger correlation between the cell angle and the mechanical parameters of the ABS structure. They also enable modeling and identification of the significant geometric parameters for the additive manufacturing process. Specifically, it was observed that the cell angle had a substantial impact on the E responses, influencing them by 55%, as well as on the Poisson coefficient responses, where the effect was notable at 80%. Additionally, the influence on lightness was observed, albeit to a lesser extent, with a 25% impact.