Additive Manufacturing-Oriented Design of Graded Lattice Structures Through Explicit Topology Optimization

2017 ◽  
Vol 84 (8) ◽  
Author(s):  
Chang Liu ◽  
Zongliang Du ◽  
Weisheng Zhang ◽  
Yichao Zhu ◽  
Xu Guo
Keyword(s):  
Topology Optimization ◽  
Structure Design ◽  
Lattice Structures ◽  
New Approach ◽  
Optimization Framework ◽  
Concurrent Optimization ◽  
Design Variables ◽  
Graded Material ◽  
Graded Lattice ◽  
Moving Morphable Components

In the present work, a new approach for designing graded lattice structures is developed under the moving morphable components/voids (MMC/MMV) topology optimization framework. The essential idea is to make a coordinate perturbation to the topology description functions (TDF) that are employed for the description of component/void geometries in the design domain. Then, the optimal graded structure design can be obtained by optimizing the coefficients in the perturbed basis functions. Our numerical examples show that the proposed approach enables a concurrent optimization of both the primitive cell and the graded material distribution in a straightforward and computationally effective way. Moreover, the proposed approach also shows its potential in finding the optimal configuration of complex graded lattice structures with a very small number of design variables employed under various loading conditions and coordinate systems.

scholarly journals Substructure-Based Topology Optimization for Symmetric Hierarchical Lattice Structures

Symmetry ◽  
2020 ◽  
Vol 12 (4) ◽  
pp. 678
Author(s):  
Zijun Wu ◽  
Renbin Xiao
Keyword(s):  
Topology Optimization ◽  
High Efficiency ◽  
Spline Interpolation ◽  
Optimization Method ◽  
Optimality Criteria ◽  
Lattice Structures ◽  
Hierarchical Lattice ◽  
B Spline ◽  
Design Variables ◽  
Optimality Criteria Method

This work presents a topology optimization method for symmetric hierarchical lattice structures with substructuring. In this method, we define two types of symmetric lattice substructures, each of which contains many finite elements. By controlling the materials distribution of these elements, the configuration of substructure can be changed. And then each substructure is condensed into a super-element. A surrogate model based on a series of super-elements can be built using the cubic B-spline interpolation. Here, the relative density of substructure is set as the design variable. The optimality criteria method is used for the updating of design variables on two scales. In the process of topology optimization, the symmetry of microstructure is determined by self-defined microstructure configuration, while the symmetry of macro structure is determined by boundary conditions. In this proposed method, because of the educing number of degree of freedoms on macrostructure, the proposed method has high efficiency in optimization. Numerical examples show that both the size and the number of substructures have essential influences on macro structure, indicating the effectiveness of the presented method.

scholarly journals Backbone cup – a structure design competition based on topology optimization and 3D printing

2016 ◽  
Vol 7 ◽  
pp. A1 ◽  
Author(s):  
Ji-Hong Zhu ◽  
Kai-Ke Yang ◽  
Wei-Hong Zhang
Keyword(s):  
Topology Optimization ◽  
3D Printing ◽  
Experimental Approach ◽  
Mechanical Performance ◽  
Turnaround Time ◽  
Structure Design ◽  
The Finite Element Method ◽  
New Approach ◽  
Design Competition ◽  
Testing Approach

This paper addresses a structure design competition based on topology optimization and 3D Printing, and proposes an experimental approach to efficiently and quickly measure the mechanical performance of the structures designed using topology optimization. Since the topology optimized structure designs are prone to be geometrically complex, it is extremely inconvenient to fabricate these designs with traditional machining. In this study, we not only fabricated the topology optimized structure designs using one kind of 3D Printing technology known as stereolithography (SLA), but also tested the mechanical performance of the produced prototype parts. The finite element method is used to analyze the structure responses, and the consistent results of the numerical simulations and structure experiments prove the validity of this new structure testing approach. This new approach will not only provide a rapid access to topology optimized structure designs verifying, but also cut the turnaround time of structure design significantly.

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.

Structural Topology Optimization Through Explicit Boundary Evolution

2016 ◽  
Vol 84 (1) ◽  
Author(s):  
Weisheng Zhang ◽  
Wanying Yang ◽  
Jianhua Zhou ◽  
Dong Li ◽  
Xu Guo
Keyword(s):  
Topology Optimization ◽  
Optimal Designs ◽  
Structural Topology ◽  
B Spline ◽  
Numerical Examples ◽  
Optimization Framework ◽  
And Topology ◽  
Spline Curves ◽  
Structural Boundary ◽  
Moving Morphable Components

Traditional topology optimization is usually carried out with approaches where structural boundaries are represented in an implicit way. The aim of the present paper is to develop a topology optimization framework where both the shape and topology of a structure can be obtained simultaneously through an explicit boundary description and evolution. To this end, B-spline curves are used to describe the boundaries of moving morphable components (MMCs) or moving morphable voids (MMVs) in the structure and some special techniques are developed to preserve the smoothness of the structural boundary when topological change occurs. Numerical examples show that optimal designs with smooth structural boundaries can be obtained successfully with the use of the proposed approach.

Application of a Ground Beam-Joint Topology Optimization Method for Multi-Piece Frame Structure Design

2008 ◽  
Vol 130 (8) ◽  
Author(s):  
Myung-Jin Kim ◽  
Gang-Won Jang ◽  
Yoon Young Kim
Keyword(s):  
Topology Optimization ◽  
Optimization Technique ◽  
Joint Stiffness ◽  
Optimization Method ◽  
Structure Design ◽  
Frame Structure ◽  
Optimal Layout ◽  
Design Variables ◽  
Discrete Values ◽  
Topology Optimization Method

When a multipiece frame structure is designed, not only its topological layout but also assembly locations should be determined. This paper presents a compliance-minimizing topology optimization technique to determine an optimal layout configuration and to suggest candidate assembly locations. The technique employs a ground beam-joint model and places candidate assembly joints where the values of joint stiffness are relatively small. The zero-length joint elements have varying stiffness controlled by real-valued design variables. Because joint stiffness values at the converged state can be utilized to select candidate assembly locations along with their strengths, the technique is extremely useful in multipiece frame structure design. Because structural properties of ground beams can have only discrete values or remain unchanged for optimization process, no poststructural modification is required in an actual manufacturing step.

Manufacturability-Oriented Ground Beam-Joint Topology Optimization for Multi-Piece Frame Structure Design

2007 ◽  
Author(s):  
Myung-Jin Kim ◽  
Gang-Won Jang ◽  
Yoon Young Kim
Keyword(s):  
Topology Optimization ◽  
Structural Modification ◽  
Joint Stiffness ◽  
Structure Design ◽  
Design Tool ◽  
Frame Structure ◽  
Structural Performance ◽  
Beam Model ◽  
Optimal Layout ◽  
Design Variables

Topology optimization is a useful design tool, but it often yields layouts difficult to manufacture without considerable post structural modification. As a result, its structural performance can be significantly deteriorated. To minimize the undesirable postprocessing, we aim to develop a manufacturability-oriented compliance-minimizing topology optimization using a ground beam model incorporating additional zero-length elastic joint elements. In the present formulation, design variables control the stiffness of zero-length elastic joints, not the stiffness of beams. Because joint stiffness values at the converged state can be utilized to select candidate assembly locations, the technique is extremely useful to design multi-piece frame structures. An optimal layout is also extracted based on the stiffness values. Because structural properties of ground beams can take only on discretely available values or remain unchanged for optimization process, no post structural modification is required in an actual manufacturing step.

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