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.

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.

Lattice Structure Design for Additive Manufacturing: Unit Cell Topology Optimization

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.

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 optimisation framework for designs for additive manufacturing combining design, manufacturing and post-processing

2021 ◽  
Vol 27 (11) ◽  
pp. 90-105
Author(s):  
Anton Wiberg ◽  
Johan Persson ◽  
Johan Ölvander
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Manufacturing Cost ◽  
Design For Additive Manufacturing ◽  
Post Processing ◽  
Process Selection ◽  
Content Type ◽  
Post Process ◽  
Alternative Designs

Purpose The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework. Design/methodology/approach A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed. Findings The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium. Originality/value The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Resting hand splint model from topology optimization to be produced by additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Paulo Reis ◽  
Mariana Volpini ◽  
Joana Pimenta Maia ◽  
Igor Batista Guimarães ◽  
Cristiane Evelise ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Thermal Comfort ◽  
Temperature Variation ◽  
Heat Diffusion ◽  
Mechanical Resistance ◽  
Manufacturing Cost ◽  
Traditional Model ◽  
Content Type ◽  
Novel Model

Purpose The purpose of this study is to validate a novel model of resting hand splint manufactured by additive manufacturing (AM) and compare it with the traditional model manufactured by high temperature thermoplastic in terms of cost, weight, volume and thermal comfort. Design/methodology/approach A novel resting hand splint model was created from the topology optimization (TO) and analyzed, by finite-element analysis, manufacturing cost and weight, with a traditional resting hand splint. A pilot clinical study was carried out to verify heat diffusion during the use of the two splints. Findings The results showed that compared with the traditional model, the novel model reduced the volume of material used by 35.48%, the weight of the orthosis by 17.56% and the maximum surface deformation by 171.17% when subjected to actuation forces. It was also verified that, when manufactured with Nylon by AM, the new model is 1.5 times cheaper than the traditional model made of Polypropylene. The result of the thermographic analysis showed greater temperature variation in the use of the traditional splint (+4.6°C) compared to the temperature variation observed in the nylon splint (2.1°C). Practical implications These results have as clinical relevance the demonstration of the feasibility of manufacturing functional orthoses that are more comfortable, cheaper and lighter than traditional ones. Originality/value This study describes the use of TO to manufacture a novel resting hand splint, which was compared with the commonly used traditional splint in terms of mechanical resistance, weight, cost and thermal comfort.

Manufacturing cost constrained topology optimization for additive manufacturing

2019 ◽  
Vol 14 (2) ◽  
pp. 213-221 ◽  
Author(s):  
Jikai Liu ◽  
Qian Chen ◽  
Xuan Liang ◽  
Albert C. To
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Cost
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