scholarly journals Potential impact of additive manufacturing and topology optimization inspired lightweight design on vehicle track performance

2021 ◽  
Author(s):  
Jan A. Tschorn ◽  
Daniel Fuchs ◽  
Thomas Vietor
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lightweight Design ◽  
Interactive Approach ◽  
Vehicle Performance ◽  
Weight Saving ◽  
Time Simulation ◽  
Reference Vehicle ◽  
The Impact ◽  
Design Freedom

AbstractThis paper describes an interactive approach for analyzing the impact of the enhanced design freedom in additive manufacturing (AM) combined with topology optimization. The main goal is to identify weight saving potentials on a holistic vehicle level and evaluate the influence on vehicle performance by means of lap time savings. Therefore lightweight use cases enabled by AM are gathered in a database. Projecting the weight reduction rates of this database to a sports car as reference vehicle by means of a weight list, CAD data and a part relation analysis leads to an overall weight saving potential. This analysis shows significant weight saving potentials for each technical section of an already lightweight design focused sports car, namely the Bugatti Chiron. The improvement in track performance considering the weight savings is put into perspective by means of lap time simulation on the Nürburgring Nordschleife and corroborate the identified weight saving potentials.

scholarly journals An efficient approach to reliability-based topology optimization for the structural lightweight design of planar continuum structures

2021 ◽  
Vol 37 ◽  
pp. 270-281
Author(s):  
Fangfang Yin ◽  
Kaifang Dang ◽  
Weimin Yang ◽  
Yumei Ding ◽  
Pengcheng Xie
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Integrated Design ◽  
Optimization Methods ◽  
Filter Function ◽  
Continuum Structures ◽  
Performance Indexes ◽  
Reliability Method ◽  
Economic Indexes ◽  
The Impact

Abstract In order to solve the application restrictions of deterministic-based topology optimization methods arising from the omission of uncertainty factors in practice, and to realize the calculation cost control of reliability-based topology optimization. In consideration of the current reliability-based topology optimization methods of continuum structures mainly based on performance indexes model with a power filter function. An efficient probabilistic reliability-based topology optimization model that regards mass and displacement as an objective function and constraint is established based on the first-order reliability method and a modified economic indexes model with a composite exponential filter function in this study. The topology optimization results obtained by different models are discussed in relation to optimal structure and convergence efficiency. Through numerical examples, it can be seen that the optimal layouts obtained by reliability-based models have an increased amount of material and more support structures, which reveals the necessity of considering uncertainty in lightweight design. In addition, the reliability-based modified model not only can obtain lighter optimal structures compared with traditional economic indexes models in most circumstances, but also has a significant advantage in convergence efficiency, with an average increase of 44.59% and 64.76% compared with the other two reliability-based models. Furthermore, the impact of the reliability index on the results is explored, which verifies the validity of the established model. This study provides a theoretical reference for lightweight or innovative feature-integrated design in engineering applications.

Topology optimization design of hydraulic valve blocks for additive manufacturing

2020 ◽  
Vol 234 (10) ◽  
pp. 1899-1912
Author(s):  
Guanlin Xie ◽  
Yongjia Dong ◽  
Jing Zhou ◽  
Zhongqi Sheng
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Hydraulic System ◽  
Optimization Design ◽  
Lightweight Design ◽  
Block Design ◽  
Reduction Rate ◽  
Material Strength ◽  
Hydraulic Valve ◽  
Valve Block

The hydraulic valve block is a core component of an integrated hydraulic system. In practical usage, it exhibits problems such as material waste, long manufacturing cycle, significant energy loss, and leakage. Based on the aforementioned existing problems, this study presents the design of the hydraulic system valve block based on the valve block design principle. The internal valve channel of the hydraulic valve block is optimized for additive manufacturing technology to avoid auxiliary drilling, solve the problem of potential liquid leakage, and shorten the manufacturing cycle. Thus, it is more suitable for the production of customized complex hydraulic valve blocks. The multiobjective topology optimization method is applied to the lightweight design of the hydraulic valve block to save resources and decrease energy consumption. The results indicate that when compared with the original model, the minimum reduction rate of pressure loss in each oil circuit orifice after optimization of the hydraulic valve block corresponds to 32.02%, the maximum corresponds to 71.38%; the maximum stress of the final design corresponds to 542.9 MPa, which satisfies the material strength requirement; and the mass is decreased by 68.9%. Thus, the lightweight design of the hydraulic valve block is realized.

scholarly journals Guidelines for Topology Optimization as Concept Design Tool and Their Application for the Mechanical Design of the Inner Frame to Support an Ancient Bronze Statue

2021 ◽  
Vol 11 (17) ◽  
pp. 7834
Author(s):  
Abas Ahmad ◽  
Michele Bici ◽  
Francesca Campana
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Early Stage ◽  
Lightweight Design ◽  
Design Tool ◽  
Design Solution ◽  
Design Activity ◽  
Concept Design ◽  
Bronze Statue ◽  
Design Requirements

For the past few decades, topology optimization (TO) has been used as a structural design optimization tool. With the passage of time, this kind of usage of TO has been extended to many application fields and branches, thanks to a better understanding of how manufacturing constraints can achieve a practical design solution. In addition, the advent of additive manufacturing and its subsequent advancements have further increased the applications of TO, raising the chance of competitive manufacturing. Design for additive manufacturing has also promoted the adoption of TO as a concept design tool of structural components. Nevertheless, the most frequent applications are related to lightweight design with or without design for assembly. A general approach to integrate TO in concept designs is still missing. This paper aims to close this gap by proposing guidelines to translate design requirements into TO inputs and to include topology and structural concerns at the early stage of design activity. Guidelines have been applied for the concept design of an inner supporting frame of an ancient bronze statue, with several constraints related to different general design requirements, i.e., lightweight design, minimum displacement, and protection of the statue’s structural weak zones to preserve its structural integrity. Starting from the critical analysis of the list of requirements, a set of concepts is defined through the application of TO with different set-ups (loads, boundary conditions, design and non-design space) and ranked by the main requirements. Finally, a validation of the proposed approach is discussed comparing the achieved results with the ones carried out through a standard iterative concept design.

Light Weighting Solutions for Additively Manufactured Aviation Components

2019 ◽  
Author(s):  
Sandeep Medikonda ◽  
Sriraghav Sridharan ◽  
Sunil Acharya ◽  
John Doyle
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lightweight Design ◽  
Structural Response ◽  
Primary Objective ◽  
Optimized Design ◽  
Discrete Optimization Problem ◽  
Maximum Deformation ◽  
Mechanical Parts ◽  
Manufacturing Methods

Abstract Recently, additive manufacturing methods have gained popularity for their ability to produce complex mechanical parts where conventional manufacturing methods are not suitable. Such methods not only offer a great sense of freedom to engineers but when combined with topology optimization tools can be used to simulate structures with complex shapes which satisfy the real-world loading constraints while requiring as little material as possible. Hence, combining topology optimization and additive production procedures offers a promising approach for obtaining optimized mechanical parts. This article presents a complete workflow for studying complex topology optimized parts that can be printed using additive manufacturing. We focus on topologically optimized design approach for additive manufacturing with case studies on lightweight design of aviation safety-critical parts. The complete workflow of such a setup is discussed. The Topology Optimization of these parts has been carried out using the Solid Isotropic Material with Penalization (SIMP) algorithm [1], where a discrete optimization problem is converted to a continuous problem. The primary objective of the optimization studies is to maximize the stiffness of the chosen parts while minimizing their mass at the same time. We also investigate the effect of design constraints to account for feasible manufacturing of the part while maintaining the structural response to performance loads. These optimized parts are then analyzed using a lumped layer approach to simulate powder bed fusion (PBF) [2] as a coupled thermal-structural analysis within ANSYS®, where the areas of maximum deformation and stress resulting from additive printing are predicted. The influence that the orientation of a part’s build direction has on the end results is investigated using a parametric study. Effect of a cartesian mesh vs a tetrahedron mesh on the results have been analyzed and best practices while working with coupled topology optimization and additive simulations have also been discussed.

scholarly journals AN APPROACH FOR TOPOLOGY OPTIMIZATION-DRIVEN DESIGN FOR ADDITIVE MANUFACTURING

2020 ◽  
Vol 1 ◽  
pp. 325-334
Author(s):  
A. Nordin
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lightweight Design ◽  
Manufacturing Cost ◽  
Design For Additive Manufacturing ◽  
Complex Tasks ◽  
Parametric Control

AbstractThis paper describes an approach for designing lightweight components produced through additive manufacturing (AM). Lightweight design is often done through topology optimization (TO). However, the process of manually interpreting mesh-based and imprecise results from a TO into a geometry that fulfils all requirements is complex. To aid in this process, this paper suggest an approach based on combining overhang-constrained TO with lattice-based TO to automate complex tasks, retain parametric control, and to minimize manufacturing cost. The approach is validated through a benchmark part.

Exploring the Effects of Additive Manufacturing Education on Students' Engineering Design Process and its Outcomes

2019 ◽  
Vol 142 (4) ◽  
Author(s):  
Rohan Prabhu ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Engineering Design ◽  
Educational Intervention ◽  
Classroom Environment ◽  
Self Efficacy ◽  
Educational Interventions ◽  
Educational Institutions ◽  
Integrate Design ◽  
The Impact ◽  
Design Freedom

AbstractResearch in additive manufacturing (AM) has increased the use of AM in many industries, resulting in a commensurate need for a workforce skilled in AM. In order to meet this need, educational institutions have undertaken different initiatives to integrate design for additive manufacturing (DfAM) into the engineering curriculum. However, limited research has explored the impact of these educational interventions in bringing about changes in the technical goodness of students' design outcomes, particularly through the integration of DfAM concepts in an engineering classroom environment. This study explores this gap using an experimental study with 193 participants recruited from a junior-level course on mechanical engineering design. The participants were split into three educational intervention groups: (1) no DfAM, (2) restrictive DfAM, and (3) restrictive and opportunistic (dual) DfAM. The effects of the educational intervention on the participants' use of DfAM were measured through changes in (1) participants' DfAM self-efficacy, (2) technical goodness of their AM design outcomes, and (3) participants' use of DfAM-related concepts when describing and evaluating their AM designs. The results showed that while all three educational interventions result in similar changes in the participants' opportunistic DfAM self-efficacy, participants who receive only restrictive DfAM inputs show the greatest increase in their restrictive DfAM self-efficacy. Further, we see that despite these differences, all three groups show a similar decrease in the technical goodness of their AM designs, after attending the lectures. A content analysis of the participants' design descriptions and evaluations revealed a simplification of their design geometries, which provides a possible explanation for the decrease in their technical goodness, despite the encouragement to utilize the design freedom of AM to improve functionality or optimize the weight of the structure. These results emphasize the need for more in-depth DfAM education to encourage the use of both opportunistic and restrictive DfAM during student design challenges. The results also highlight the possible influence of how the design problem is stated on the use of DfAM in solving it.

Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation

2017 ◽  
Vol 23 (4) ◽  
pp. 660-677 ◽  
Author(s):  
Lin Cheng ◽  
Pu Zhang ◽  
Emre Biyikli ◽  
Jiaxi Bai ◽  
Joshua Robbins ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Cellular Structure ◽  
Lightweight Design ◽  
Scaling Law ◽  
Variable Density ◽  
Cellular Structures ◽  
Efficient Design ◽  
Content Type

Purpose The purpose of the paper is to propose a homogenization-based topology optimization method to optimize the design of variable-density cellular structure, in order to achieve lightweight design and overcome some of the manufacturability issues in additive manufacturing. Design/methodology/approach First, homogenization is performed to capture the effective mechanical properties of cellular structures through the scaling law as a function their relative density. Second, the scaling law is used directly in the topology optimization algorithm to compute the optimal density distribution for the part being optimized. Third, a new technique is presented to reconstruct the computer-aided design (CAD) model of the optimal variable-density cellular structure. The proposed method is validated by comparing the results obtained through homogenized model, full-scale simulation and experimentally testing the optimized parts after being additive manufactured. Findings The test examples demonstrate that the homogenization-based method is efficient, accurate and is able to produce manufacturable designs. Originality/value The optimized designs in our examples also show significant increase in stiffness and strength when compared to the original designs with identical overall weight.

scholarly journals The Effect of Javanese Language Videos with a Community Based Interactive Approach Method as an Educational Instrument for Knowledge, Perception, and Adherence amongst Tuberculosis Patients

Pharmacy ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 86
Author(s):  
Fauna Herawati ◽  
Yuni Megawati ◽  
Aslichah ◽  
Retnosari Andrajati ◽  
Rika Yulia
Keyword(s):  
Intervention Group ◽  
Personal Control ◽  
Control Group ◽  
P Value ◽  
Interactive Approach ◽  
Community Based ◽  
Tuberculosis Patients ◽  
Level Of Knowledge ◽  
The Impact

The long period of tuberculosis treatment causes patients to have a high risk of forgetting or stopping the medication altogether, which increases the risk of oral anti-tuberculosis drug resistance. The patient’s knowledge and perception of the disease affect the patient’s adherence to treatment. This research objective was to determine the impact of educational videos in the local language on the level of knowledge, perception, and adherence of tuberculosis patients in the Regional General Hospital (RSUD) Bangil. This quasi-experimental study design with a one-month follow-up allocated 62 respondents in the intervention group and 60 in the control group. The pre- and post-experiment levels of knowledge and perception were measured with a validated set of questions. Adherence was measured by pill counts. The results showed that the intervention increases the level of knowledge of the intervention group higher than that of the control group (p-value < 0.05) and remained high after one month of follow-up. The perceptions domains that changed after education using Javanese (Ngoko) language videos with the Community Based Interactive Approach (CBIA) method were the timeline, personal control, illness coherence, and emotional representations (p-value < 0.05). More than 95% of respondents in the intervention group take 95% of their pill compared to 58% of respondents in the control group (p-value < 0.05). Utilization of the local languages for design a community-based interactive approach to educate and communicate is important and effective.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

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