Three-dimensional high resolution topology optimization considering additive manufacturing constraints

2020 ◽  
Vol 35 ◽  
pp. 101224 ◽  
Author(s):  
Kaiqing Zhang ◽  
Gengdong Cheng
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
High Resolution ◽  
Three Dimensional ◽  
Manufacturing Constraints

Incorporating Manufacturing Constraints in Topology Optimization Methods: A Survey

2017 ◽  
Author(s):  
Alok Sutradhar ◽  
Jaejong Park ◽  
Payam Haghighi ◽  
Jacob Kresslein ◽  
Duane Detwiler ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Methods ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Manufacturing Constraints ◽  
Post Processing ◽  
Optimization Framework ◽  
Manufacturing Methods ◽  
Traditional Manufacturing

Topology optimization provides optimized solutions with complex geometries which are often not suitable for direct manufacturing without further steps or post-processing by the designer. There has been a recent progression towards linking topology optimization with additive manufacturing, which is less restrictive than traditional manufacturing methods, but the technology is still in its infancy being costly, time-consuming, and energy inefficient. For applications in automotive or aerospace industries, the traditional manufacturing processes are still preferred and utilized to a far greater extent. Adding manufacturing constraints within the topology optimization framework eliminates the additional design steps of interpreting the topology optimization result and converting it to viable manufacturable parts. Furthermore, unintended but inevitable deviations that occur during manual conversion from the topology optimized result can be avoided. In this paper, we review recent advances to integrate (traditional) manufacturing constraints in the topology optimization process. The focus is on the methods that can create manufacturable and well-defined geometries. The survey will discuss the advantages, limitations, and related challenges of manufacturability in topology optimization.

Direct Solid Element Slicing in Topology Optimization for Additive Manufacturing

2019 ◽  
Author(s):  
Dylan Bender ◽  
Ahmad Barari
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Closed Loop ◽  
Element Model ◽  
Solid Model ◽  
Manufacturing Constraints ◽  
Manufacturing Process Planning ◽  
Almost All ◽  
The Finite Element Model ◽  
Direct Solid

Abstract The traditional input to almost all commercially available Additive Manufacturing (AM) systems is in STL (Standard Tessellation Language) format, which represents a solid model by its tessellated surfaces. This does not allow transferring the entire information of a solid model to the additive manufacturing preprocessing system. However, in some recent applications such as additive manufacturing preprocessing simulation, closed-loop of topology optimization and additive manufacturing process planning, and AM-based design optimization the full access to the solid model information is necessary. Slicing of the finite element model directly is introduced in this paper. The presented approach enables access to the entire solid model information during the AM preprocessing tasks with a focus on coupling the topology optimization in the design process with the actual manufacturing constraints.

scholarly journals Developing Topology Optimization with Additive Manufacturing Constraints in ANSYS®

2018 ◽  
Vol 51 (11) ◽  
pp. 1359-1364 ◽  
Author(s):  
Davin Jankovics ◽  
Hossein Gohari ◽  
Mohsen Tayefeh ◽  
Ahmad Barari
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Constraints

Gradient-Based Multi-Component Topology Optimization for Additive Manufacturing (MTO-A)

2017 ◽  
Author(s):  
Yuqing Zhou ◽  
Kazuhiro Saitou
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Simultaneous Optimization ◽  
Minimum Length ◽  
Manufacturing Constraints ◽  
Component Level ◽  
Component Size ◽  
Design Variables ◽  
Gradient Based ◽  
Minimum Length Scale

Topology optimization for additive manufacturing has been limited to the component-level designs with the component size smaller than the printer’s build volume. To enable the design of structures larger than the printer’s build volume, this paper presents a gradient-based multi-component topology optimization framework for structures assembled from components built by additive manufacturing. Constraints on component geometry for additive manufacturing are incorporated in the density-based topology optimization, with additional design variables specifying fractional component membership. For each component, constraints on build size, enclosed voids, overhangs, and the minimum length scale are imposed during the simultaneous optimization of overall base topology and component partitioning. The preliminary result on a minimum compliance structure shows promising advantages over the conventional monolithic topology optimization. Manufacturing constraints previously applied to monolithic topology optimization gain new interpretations when applied to multi-component assemblies, which can unlock richer design space for topology exploration.

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

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.

scholarly journals Mechanisms and modeling of electrohydrodynamic phenomena

2018 ◽  
Vol 5 (1) ◽  
Author(s):  
Jack Zhou ◽  
Dajing Gao ◽  
Donggang Yao ◽  
Steven K. Leist ◽  
Yifan Fei
Keyword(s):  
Additive Manufacturing ◽  
High Resolution ◽  
Inkjet Printing ◽  
Scaling Laws ◽  
Current Trend ◽  
Three Dimensional ◽  
Theoretical Models ◽  
Manufacturing Method ◽  
Cone Development ◽  
Key Factor

The purpose of this paper is to review the mechanisms of electrohydrodynamic (EHD) phenomenon. From this review, researchers and students can learn principles and development history of EHD. Significant progress has been identified in research and development of EHD high-resolution deposition as a direct additive manufacturing method, and more effort will be driven to this direction soon. An introduction is given about current trend of additive manufacturing and advantages of EHD inkjet printing. Both theoretical models and experiment approaches about the formation of cone, development of cone-jet transition and stability of jet are presented. The formation of a stable cone-jet is the key factor for precision EHD printing which will be discussed. Different scaling laws can be used to predict the diameter of jet and emitted current in different parametrical ranges. The information available in this review builds a bridge between EHD phenomenon and three-dimensional high-resolution inkjet printing.

Topology Optimization for Additive Manufacturing Considering Layer-Based Minimum Feature Sizes

2017 ◽  
Author(s):  
Mikhail Osanov ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Design Tool ◽  
Geometric Constraints ◽  
Layer By Layer ◽  
Simple Modification ◽  
Complex Structural ◽  
Manufacturing Technologies

The rapid advance of additive manufacturing technologies has provided new opportunities for creating complex structural shapes. In order to fully exploit these opportunities, however, engineers must re-think the design process and leverage these new capabilities while respecting manufacturing constraints inherent in various processes. Topology optimization, as a free-from design tool, is a potentially powerful approach to addressing this design challenge provided the manufacturing process is properly accounted for. This work examines geometric constraints related to feature size and the layer-by-layer nature of the manufacturing process. A simple modification to the Heaviside Projection Method, an approach for naturally achieving geometric constraints in topology optimization, is proposed and demonstrated to have clear, understandable impact on three-dimensional optimized beam designs.

An Investigation of Key Design for Additive Manufacturing Constraints in Multimaterial Three-Dimensional Printing

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Nicholas Meisel ◽  
Christopher Williams
Keyword(s):  
Additive Manufacturing ◽  
Statistical Significance ◽  
Three Dimensional ◽  
Manufacturing Constraints ◽  
Support Material ◽  
Design For Additive Manufacturing ◽  
Three Dimensional Printing ◽  
Automated Method ◽  
Key Variables ◽  
The One

The PolyJet material jetting process is uniquely qualified to create complex, multimaterial structures. However, key manufacturing constraints need to be explored and understood in order to guide designers in their use of the PolyJet process including (1) minimum manufacturable feature size, (2) removal of support material, (3) survivability of small features, and (4) the self-supporting angle in the absence of support material. The authors use a design of experiments (DOE) approach to identify the statistical significance of geometric and process parameters and to quantify the relationship between these significant parameters and part manufacturability. The results from this study include the identification of key variables, relationships, and quantitative design thresholds necessary to establish a preliminary set of design for additive manufacturing (DfAM) guidelines for material jetting. Experimental design studies such as the one in this paper are crucial to provide designers with the knowledge to ensure that their proposed designs are manufacturable with the PolyJet process, whether designed manually or by an automated method, such as topology optimization (TO).

scholarly journals Design for Additive Manufacturing of Conformal Cooling Channels Using Thermal-Fluid Topology Optimization and Application in Injection Molds

2018 ◽  
Author(s):  
Tong Wu ◽  
Andres Tovar
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Conceptual Design ◽  
Three Dimensional ◽  
Analytical Sensitivity ◽  
Material Distribution ◽  
Cooling Systems ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

Additive manufacturing allows the fabrication parts and tools of high complexity. This capability challenges traditional guidelines in the design of conformal cooling systems in heat exchangers, injection molds, and other parts and tools. Innovative design methods, such as network-based approaches, lattice structures, and structural topology optimization have been used to generate complex and highly efficient cooling systems; however, methods that incorporate coupled thermal and fluid analysis remain scarce. This paper introduces a coupled thermal-fluid topology optimization algorithm for the design of conformal cooling channels. With this method, the channel position problem is replaced to a material distribution problem. The material distribution directly depends on the effect of flow resistance, heat conduction, as well as forced and natural convection. The problem is formulated based on a coupling of Navier-Stokes equations and convection-diffusion equation. The problem is solved by gradient-based optimization after analytical sensitivity derived using the adjoint method. The algorithm leads a two -dimensional conceptual design having optimal heat transfer and balanced flow. The conceptual design is converted to three-dimensional channels and mapped to a morphological surface conformal to the injected part. The method is applied to design an optimal conformal cooling for a real three dimensional injection mold. The feasibility of the final designs is verified through simulations. The final designs can be exported as both three-dimensional graphic and surface mesh CAD format, bringing the manufacture department the convenience to run the tool path for final fitting.

scholarly journals Optimal design of three-dimensional non-uniform nylon lattice structures for selective laser sintering manufacturing

2018 ◽  
Vol 10 (7) ◽  
pp. 168781401879083 ◽  
Author(s):  
Xin Jin ◽  
Guo Xi Li ◽  
Meng Zhang
Keyword(s):  
Mechanical Properties ◽  
Topology Optimization ◽  
Optimal Design ◽  
Cell Size ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Manufacturing Constraints ◽  
Lattice Structures ◽  
Cell Type

As a kind of novel multifunctional structure with three-dimensional pores characterized by low relative density, lattice structures can attain a lightweight design while maintaining high specific mechanical properties in three-dimensional solid structures. Focusing on the challenge of finding the optimal design of lattice structures in the design object, a design and modeling method of non-uniform three-dimensional lattice structures is proposed while ensuring the selective laser sintering manufacturability. Optimization for cell type, cell size, and strut size distribution of lattices is specified with the mechanical properties analyzed and the material model calculated beforehand. The manufacturing constraints are analyzed and expressed in topology optimization and the optimal distribution of topology optimization results is mapped to the strut size distribution of lattice cells. The rapid and automatic computer-aided design modeling of optimized structures is realized by the parametric definition and assembling of lattice components. Finally, the non-uniform structures are successfully manufactured by selective laser sintering and it is shown by means of finite element analysis and experiments that the proposed design approach can improve the mechanical performance compared to the uniform lattice structure under the same weight reduction. And for the design object in this study, body-centered structure with cell size [Formula: see text]mm is chosen as the optimal cell type and cell size under the given selective laser sintering manufacturing constraints.

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