Numerical and Experimental Insights into Crack Propagation in 3D-Printed ABS Using XFEM and Tensile Analysis

This study investigates the mechanical properties and crack propagation behavior of 3D-printed Acrylonitrile Butadiene Styrene (ABS) by integrating numerical simulations with experimental tensile testing. Utilizing the eXtended Finite Element Method (XFEM) within the Abaqus software, the research examines the damage evolution in ABS specimens under Mode I loading, focusing on the influence of factors such as print orientation, infill density, and layer thickness on mechanical performance. The numerical model, validated through uniaxial tensile tests conducted at a rate of 10 mm/min on ABS specimens with an initial notch, accurately captures the crack propagation process, revealing a two-stage fracture evolution: an initial stable phase over the first 60% of the specimen’s lifetime, followed by rapid crack growth leading to structural failure. Three distinct phases of crack propagation velocity are identified: low velocity during initiation, a quasi-static intermediate phase, and a high-velocity unstable phase, correlating with the evolution of the stress intensity factor. The close agreement between numerical and experimental results underscores the reliability of XFEM for modeling crack behavior, providing critical insights into optimizing 3D printing parameters to enhance the mechanical properties, structural integrity, and durability of ABS components for diverse engineering applications.