A Topology Optimization Method for Stochastic Lattice Structures

AbstractStochastic lattice structures are very powerful solutions for filling three-dimensional spaces using a generative algorithm. They are suitable for 3D printing and are well appropriate to structural optimization and mass distribution, allowing for high-performance and low-weight structures. The paper shows a method, developed in the Rhino-Grasshopper environment, to distribute lattice structures until a goal is achieved, e.g. the reduction of the weight, the harmonization of the stresses or the limitation of the strain. As case study, a cantilever beam made of Titan alloy, by means of SLS technology has been optimized. The results of the work show the potentiality of the methodology, with a very performing structure and low computational efforts.

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Additively Manufactured Continuous Fibre-Reinforced Thermoplastics for Mechanisms Subjected to Predominant Inertial Load: A Case Study

ASME 2020 Conference on Smart Materials, Adaptive Structures and Intelligent Systems ◽

10.1115/smasis2020-2320 ◽

2020 ◽

Author(s):

Luca Luzi ◽

Giacomo Quercioli ◽

Riccardo Pucci ◽

Guido Bocchieri ◽

Rocco Vertechy ◽

...

Keyword(s):

Aluminum Alloy ◽

Topology Optimization ◽

High Performance ◽

Permanent Magnet Synchronous Motor ◽

Three Dimensional ◽

Direct Drive ◽

Continuous Fibre ◽

Mechanical Components ◽

Reinforced Thermoplastics

Abstract In the last decade, the adoption of additive manufacturing technologies (AMT) (3D printing) has increased significantly in many fields of engineering, initially only for rapid prototyping and more recently also for the production of finished parts. With respect to the long-established material subtractive technologies (MST), AMT is capable to overcome several limitations related to the shape realization of high-performance mechanical components such as those conceived via topology optimization and generative design approaches. In the field of structures and mechanisms, a major advantage of AMT over MST is that, for the same loading and constraining conditions (including kinematic and overall encumbrance), it enables the realization of mechanical components with similar stiffness but smaller volume (thus smaller weight, density being equal). Recently, the potentialities of AMT have also been increased by the introduction of the fuse filament deposition modeling (FDM) of continuous fibre-reinforced thermoplastics (CFRT), which combines the ease of processing of plastic AMT with the strength and specific modulus of the printed components that are comparable to those attainable via metallic AMT. In this context, the present paper investigates the potentialities of FDM-CFRT for the realization of mechanisms subjected to predominant inertial loads such as those found in automated packaging machinery. As a case study a Stephenson six-bar linkage powered in direct drive by a permanent magnet synchronous motor is considered. Starting from an existing mechanism realized in aluminum alloy with traditional MST, a newer version to be realized with FDM-CFRT has been conceived by keeping the kinematics fixed and by redesigning the links via three-dimensional topology optimization. To provide a fair comparison with the more traditional design/manufacturing approach, size optimization of the original mechanism made in aluminum alloy has also been performed. Comparison of the two versions of the mechanism highlights the superior performances of the one manufactured via FDM-CFRT in terms of weight, motor torque requirements and motion precision.

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A new three-dimensional topology optimization method based on moving morphable components (MMCs)

Computational Mechanics ◽

10.1007/s00466-016-1365-0 ◽

2016 ◽

Vol 59 (4) ◽

pp. 647-665 ◽

Cited By ~ 46

Author(s):

Weisheng Zhang ◽

Dong Li ◽

Jie Yuan ◽

Junfu Song ◽

Xu Guo

Keyword(s):

Topology Optimization ◽

Three Dimensional ◽

Optimization Method ◽

Moving Morphable Components ◽

Topology Optimization Method

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Lattice Structure Design for Additive Manufacturing: Unit Cell Topology Optimization

Volume 2A: 45th Design Automation Conference ◽

10.1115/detc2019-97863 ◽

2019 ◽

Author(s):

Bradley Hanks ◽

Mary Frecker

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Lattice Structure ◽

Optimization Method ◽

Structure Design ◽

Unit Cell ◽

Lattice Structures ◽

Design For Additive Manufacturing ◽

Structure Topology

Abstract Additive manufacturing is a developing technology that enhances design freedom at multiple length scales, from the macroscale, or bulk geometry, to the mesoscale, such as lattice structures, and even down to tailored microstructure. At the mesoscale, lattice structures are often used to replace solid sections of material and are typically patterned after generic topologies. The mechanical properties and performance of generic unit cell topologies are being explored by many researchers but there is a lack of development of custom lattice structures, optimized for their application, with considerations for design for additive manufacturing. This work proposes a ground structure topology optimization method for systematic unit cell optimization. Two case studies are presented to demonstrate the approach. Case Study 1 results in a range of unit cell designs that transition from maximum thermal conductivity to minimization of compliance. Case Study 2 shows the opportunity for constitutive matching of the bulk lattice properties to a target constitutive matrix. Future work will include validation of unit cell modeling, testing of optimized solutions, and further development of the approach through expansion to 3D and refinement of objective, penalty, and constraint functions.

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A Variational Art Algorithm for Image Generation

Leonardo ◽

10.1162/leon_a_00914 ◽

2016 ◽

Vol 49 (3) ◽

pp. 226-231

Author(s):

Yoon Young Kim ◽

Jae Chun Ryu ◽

Eunil Kim ◽

Hyoungkee Kim ◽

Byungseong Ahn

Keyword(s):

Topology Optimization ◽

System Design ◽

Optimization Algorithm ◽

Three Dimensional ◽

Optimization Method ◽

Image Generation ◽

System A ◽

Path System ◽

Virtual System ◽

Topology Optimization Method

The authors propose a variational art algorithm: a virtual system-based optimization algorithm developed for generating images. Observing that the topology optimization method used for multiphysics system design can produce two- or three-dimensional layouts without baselines, the authors propose to expand it beyond engineering applications for generating images. They have devised a virtual physical system—a heat-path system—that “interprets” the optimization-based process of image generation as the simultaneous drawing of multiple strokes in a painting.

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Designing of Topology Optimized Parts for Additive Manufacturing

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.822.526 ◽

2019 ◽

Vol 822 ◽

pp. 526-533

Author(s):

Alexey Orlov ◽

Dmitriy V. Masaylo ◽

Igor A. Polozov ◽

Pu Guang Ji

Keyword(s):

Numerical Simulation ◽

Topology Optimization ◽

Additive Manufacturing ◽

Strain State ◽

New Products ◽

Optimization Method ◽

Additive Technologies ◽

Lattice Structures ◽

Initial Material ◽

Topology Optimization Method

Due to the additive manufacturing process concept - layered synthesis of products, it becomes necessary to apply new approaches to the design of parts. One of the main tools that need to operate is numerical simulation, capable, with a skilful approach, to give an engineer an integrated procedure to the development of new products. Numerical modeling, in addition to carrying out strength calculations, includes topology optimization and the creation of lattice structures, through which it is possible to create lightweight products. New design meets requirements of strength characteristics. The use of this tool leads to a reduction in the amount of initial material and as a result - cost saving. In this paper, using the bracket as an example, was used the topology optimization method with subsequent redesign. The paper presents the results of calculations of the stress-strain state of the initial and final structures, allowing estimating the possible reduction in the mass of the product and the amount of consumable material in the manufacture of additive technologies.

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W121005 Development of high-performance take-out robots for injection molding machines using a topology optimization method

The Proceedings of Mechanical Engineering Congress Japan ◽

10.1299/jsmemecj.2012._w121005-1 ◽

2012 ◽

Vol 2012 (0) ◽

pp. _W121005-1-_W121005-2

Author(s):

Takayo KOTANI

Keyword(s):

Topology Optimization ◽

Injection Molding ◽

High Performance ◽

Optimization Method ◽

Topology Optimization Method

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Toward the integration of lattice structure-based topology optimization and additive manufacturing for the design of turbomachinery components

Advances in Mechanical Engineering ◽

10.1177/1687814019859789 ◽

2019 ◽

Vol 11 (8) ◽

pp. 168781401985978

Author(s):

Enrico Boccini ◽

Rocco Furferi ◽

Lapo Governi ◽

Enrico Meli ◽

Alessandro Ridolfi ◽

...

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Lattice Structure ◽

Three Dimensional ◽

Optimization Method ◽

Lattice Structures ◽

Stiffness Properties ◽

Maximum Stiffness ◽

Layer Manufacturing ◽

Innovative Materials

Used in several industrial fields to create innovative designs, topology optimization is a method to design a structure characterized by maximum stiffness properties and reduced weights. By integrating topology optimization with additive layer manufacturing and, at the same time, by using innovative materials such as lattice structures, it is possible to realize complex three-dimensional geometries unthinkable using traditional subtractive techniques. Surprisingly, the extraordinary potential of topology optimization method (especially when coupled with additive manufacturing and lattice structures) has not yet been extensively developed to study rotating machines. Based on the above considerations, the applicability of topology optimization, additive manufacturing, and lattice structures to the fields of turbomachinery and rotordynamics is here explored. Such techniques are applied to a turbine disk to optimize its performance in terms of resonance and mass reduction. The obtained results are quite encouraging since this approach allows improving existing turbomachinery components’ performance when compared with traditional one.

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Topology Optimization and Prototype of a Three-Dimensional Printed Compliant Finger for Grasping Vulnerable Objects With Size and Shape Variations

Journal of Mechanisms and Robotics ◽

10.1115/1.4039972 ◽

2018 ◽

Vol 10 (4) ◽

Cited By ~ 8

Author(s):

Chih-Hsing Liu ◽

Chen-Hua Chiu ◽

Ta-Lun Chen ◽

Tzu-Yang Pai ◽

Mao-Cheng Hsu ◽

...

Keyword(s):

Topology Optimization ◽

Industrial Robot ◽

Low Cost ◽

Three Dimensional ◽

Optimization Method ◽

Size And Shape ◽

Flexible Filament ◽

Pick And Place ◽

Robotic Automation ◽

Topology Optimization Method

This study presents a topology optimization method to synthesize an innovative compliant finger for grasping objects with size and shape variations. The design domain of the compliant finger is a trapezoidal area with one input and two output ports. The topology optimized finger design is prototyped by three-dimensional (3D) printing using flexible filament, and be used in the developed gripper module, which consists of one actuator and two identical compliant fingers. Both fingers are actuated by one displacement input, and can grip objects through elastic deformation. The gripper module is mounted on an industrial robot to pick and place a variety of objects to demonstrate the effectiveness of the proposed design. The results show that the developed compliant finger can be used to handle vulnerable objects without causing damage to the surface of grasped items. The proposed compliant finger is a monolithic and low-cost design, which can be used to resolve the challenge issue for robotic automation of irregular and vulnerable objects.

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Level Set-Based Topology Optimization Method for Thermal Problems Considering Design-Dependent Boundary Effects

Volume 5: 35th Design Automation Conference, Parts A and B ◽

10.1115/detc2009-86618 ◽

2009 ◽

Author(s):

Takayuki Yamada ◽

Shinji Nishiwaki ◽

Atsuro Iga ◽

Kazuhiro Izui ◽

Masataka Yoshimura

Keyword(s):

Field Theory ◽

Topology Optimization ◽

Level Set ◽

Phase Field ◽

Three Dimensional ◽

Optimization Method ◽

Interface Energy ◽

Total Potential ◽

Level Set Function ◽

Topology Optimization Method

This paper proposes a new level set-based topology optimization method for thermal problems that deal with generic heat transfer boundaries including design-dependent boundary conditions, based on the level set method and the concept of the phase field theory. First, a topology optimization method using a level set model incorporating a fictitious interface energy derived from the concept of the phase field theory is briefly discussed. Next, a generic optimization problem for thermal problems is formulated based on the concept of total potential energy. An optimization algorithm that uses the Finite Element Method when solving the equilibrium equation and updating the level set function is then constructed. Finally, several three-dimensional numerical examples are provided to confirm the utility and validity of the proposed topology optimization method.

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