Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing

2017 ◽  
Author(s):  
Long Jiang ◽  
Hang Ye ◽  
Chi Zhou ◽  
Shikui Chen ◽  
Wenyao Xu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Level Set ◽  
Manufacturing Process ◽  
Rational Design ◽  
Optimization Method ◽  
Significant Advance ◽  
Original Design ◽  
Computational Framework ◽  
Multi Scale

The significant advance in the boosted fabrication speed and printing resolution of additive technology has considerably increased the capability of achieving product designs with high geometric complexity. The prefabrication computation has been increasingly important and is coming to be the bottleneck in the additive manufacturing process. In this paper, the authors devise an integrated computational framework by synthesizing the parametric level set-based topology optimization method with the DLP-based SLA process for intelligent design and additive manufacturing of not only single material structures but also multi-scale, multi-functional structures. The topology of the design is optimized with a new distance-regularized parametric level set method considering the prefabrication computation. offering the flexibility and robustness of the structural design that the conventional methods could not provide. The output of the framework is a set of mask images which can be directly used in the additive manufacturing process. The proposed approach seamlessly integrates the rational design and manufacturing to reduce the complexity of the computationally-expensive prefabrication process. Two test examples, including a freeform 3D cantilever beam and a multi-scale meta-structure, are utilized to demonstrate the performance of the proposed approach. Both the simulation and experimental results verified that the new rational design could significantly reduce the prefabrication computation cost without affecting the original design intent or sacrificing original functionality.

Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Long Jiang ◽  
Hang Ye ◽  
Chi Zhou ◽  
Shikui Chen
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Level Set ◽  
Rational Design ◽  
Computational Cost ◽  
Significant Advance ◽  
Free Form ◽  
Geometric Complexity ◽  
Original Design ◽  
Design And Manufacturing

The significant advance in the boosted fabrication speed and printing resolution of additive manufacturing (AM) technology has considerably increased the capability of achieving product designs with high geometric complexity and provided tremendous potential for mass customization. However, it is also because of geometric complexity and large quantity of mass-customized products that the prefabrication (layer slicing, path planning, and support generation) is becoming the bottleneck of the AM process due to the ever-increasing computational cost. In this paper, the authors devise an integrated computational framework by synthesizing the parametric level set-based topology optimization method with the stereolithography (SLA)-based AM process for intelligent design and manufacturing of multiscale structures. The topology of the design is optimized with a distance-regularized parametric level set method considering the prefabrication computation. With the proposed framework, the structural topology optimization not only can create single material structure designs but also can generate multiscale, multimaterial structures, offering the flexibility and robustness of the structural design that the conventional methods could not provide. The output of the framework is a set of mask images that can be directly used in the AM process. The proposed approach seamlessly integrates the rational design and manufacturing to reduce the numerical complexity of the computationally expensive prefabrication process. More specifically, the prefabrication-friendly design and optimization procedure are devised to drastically eliminate the redundant computations in the traditional framework. Two test examples, including a free-form 3D cantilever beam and a multiscale meta-structure, are utilized to demonstrate the performance of the proposed approach. Both the simulation and experimental results verified that the new rational design could significantly reduce the prefabrication computation cost without affecting the original design intent or sacrificing the original functionality.

Computational Design and Additive Manufacturing of Conformal Metasurfaces by Combining Topology Optimization With Riemann Mapping Theorem

2017 ◽  
Author(s):  
Panagiotis Vogiatzis ◽  
Ming Ma ◽  
Shikui Chen ◽  
Xianfeng David Gu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Conformal Mapping ◽  
Level Set ◽  
Computational Design ◽  
Unit Cell ◽  
Free Form ◽  
Computational Framework ◽  
Riemann Mapping Theorem ◽  
Free Form Surfaces

In this paper, we present a computational framework for computational design and additive manufacturing of spatial free-form periodic metasurfaces. The proposed scheme rests on the level-set based topology approach and the conformal mapping theory. A 2D unit cell of metamaterial with tailored effective properties is created using the level-set based topology optimization method. The achieved unit cell is further mapped to the 3D quad meshes on a free-form surface by applying the conformal mapping method which can preserve the local shape and angle when mapping the 2D design to a 3D surface. The proposed level-set based optimization methods not only can act as a motivator for design synthesis, but also can be seamlessly hooked with additive manufacturing with no need of CAD reconstructions. The proposed computational framework provides a solution to increasing applications involving innovative metamaterial designs on free-form surfaces in different fields of interest. The performance of the proposed scheme is illustrated through a benchmark example where a negative-Poisson’s-ratio unit cell pattern is mapped to a 3D human face and fabricated through additive manufacturing.

scholarly journals Topology Optimization Considering Porosity Defects in Metal Additive Manufacturing

2021 ◽  
Vol 11 (12) ◽  
pp. 5578
Author(s):  
Shuangyuan Cao ◽  
Hanbin Wang ◽  
Xiao Lu ◽  
Jianbin Tong ◽  
Zhongqi Sheng
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Level Set ◽  
Optimization Model ◽  
Optimization Method ◽  
Topological Sensitivity ◽  
Classical Level ◽  
Porosity Defects ◽  
Two Phases ◽  
Metal Additive

In this paper, considering the porosity defects of Additive Manufacturing (AM), a level set topology optimization method for AM with porosity constraints is proposed. The concept of topological sensitivity is used to formulate a global porosity constraint function in the proposed method, and a level set topology optimization model considering porosity defects is obtained. To improve the robustness of the algorithm, the topology optimization model is solved in two phases. At first, the classical level set method without the porosity constraint is used to initially optimize the structure. During this process, the hole nucleation method combining bi-directional evolutionary structural optimization (BESO) and the topological sensitivity is used. Secondly, the topology optimization considering the effects of porosity is implemented on the preliminary optimization results. After performing the two-step optimization, a robust structure that alleviates the harmful impact of porosity defects is obtained. Finally, the robustness and effectiveness of the proposed method are validated by several two-dimensional numerical examples.

scholarly journals A multi-scale multi-physics modeling framework of laser powder bed fusion additive manufacturing process

2018 ◽  
Vol 73 (3) ◽  
pp. 151-157 ◽  
Author(s):  
Jing Zhang ◽  
Yi Zhang ◽  
Weng Hoh Lee ◽  
Linmin Wu ◽  
Hyun-Hee Choi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Modeling Framework ◽  
Powder Bed ◽  
Multi Scale ◽  
Physics Modeling

Optimal Viscous Damper Placement Using Level Set Topology Optimization Method

2010 ◽  
Author(s):  
Masoud Ansari ◽  
Amir Khajepour ◽  
Ebrahim Esmailzadeh
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Discrete Optimization ◽  
Optimization Problem ◽  
Minimum Energy ◽  
Optimization Method ◽  
Discrete Optimization Problem ◽  
Placement Problem ◽  
New Approach ◽  
Optimal Damping

Vibration control has always been of great interest for many researchers in different fields, especially mechanical and civil engineering. One of the key elements in control of vibration is damper. One way of optimally suppressing unwanted vibrations is to find the best locations of the dampers in the structure, such that the highest dampening effect is achieved. This paper proposes a new approach that turns the conventional discrete optimization problem of optimal damper placement to a continuous topology optimization. In fact, instead of considering a few dampers and run the discrete optimization problem to find their best locations, the whole structure is considered to be connected to infinite numbers of dampers and level set topology optimization will be performed to determine the optimal damping set, while certain number of dampers are used, and the minimum energy for the system is achieved. This method has a few major advantages over the conventional methods, and can handle damper placement problem for complicated structures (systems) more accurately. The results, obtained in this research are very promising and show the capability of this method in finding the best damper location is structures.

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