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.

Optimum design of automobile components using lattice structures for additive manufacturing

2020 ◽  
Vol 62 (6) ◽  
pp. 633-639 ◽  
Author(s):  
Büşra Aslan ◽  
Ali Rıza Yıldız
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Design ◽  
Lattice Structure ◽  
Structure Optimization ◽  
The Finite Element Method ◽  
Special Effect ◽  
Design Structure ◽  
Complex Models ◽  
Automobile Components

Abstract In today’s world, reducing fuel consumption is one of the most important goals for the automotive industry. For this reason, weight reduction is one of the main topics in this research and for various companies. In this research, topology optimization was conducted on a suspension arm as a means of ensuring balance in automobiles. Subsequently, the model, formed by topology optimization was filled with a lattice structure and re-optimized by size optimization to obtain optimum dimensions for the model. These operations are described as lattice structure optimization. Additive manufacturing (3D printer) is necessary to produce complex models (after topology and lattice structure optimization). A static analysis of the new models was conducted by using the finite element method, and the results were compared with those of the initial design of the model. As a result of the comparison, positive results were obtained, and it was shown that topology optimization and lattice structural optimization could be used in the design of vehicle elements. According to the results obtained from lattice structure optimization, design structure can be formed more reliably than via topology optimization. In addition, both configurations and layouts of the cellular structures have a special effect on the overall performance of the lattice structure.

scholarly journals Lightweight Design of Front Suspension Upright of Electric Formula Car Based on Topology Optimization Method

2020 ◽  
Vol 11 (1) ◽  
pp. 15 ◽  
Author(s):  
Jixiong Li ◽  
Jianliang Tan ◽  
Jianbin Dong
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Lightweight Design ◽  
Geometric Model ◽  
Load Condition ◽  
Optimization Method ◽  
Structure Design ◽  
Front Suspension ◽  
Emergency Braking ◽  
Topology Optimization Method

In order to obtain a lightweight front upright of an electric formula car’s suspension, the topology optimization method is used in the front upright structure design. The mathematical model of the lightweight optimization design is constructed, and the geometric model of the initial design of the front upright is subjected to the ultimate load condition. The structural optimization of a front upright resulted in the mass reduction of the upright by 60.43%. The optimized model was simulated and verified regarding the strength, stiffness, and safety factor under three different conditions, namely turning braking, emergency braking, and sharp turning. In the experiment, the uprights were machined and assembled and integrated into the racing suspension. The experimental results showed that the optimized front uprights met the requirements of performance.

scholarly journals A Realization Method for Transforming a Topology Optimization Design into Additive Manufacturing Structures

Engineering ◽  
2018 ◽  
Vol 4 (2) ◽  
pp. 277-285 ◽  
Author(s):  
Shutian Liu ◽  
Quhao Li ◽  
Junhuan Liu ◽  
Wenjiong Chen ◽  
Yongcun Zhang
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Design

scholarly journals Advanced Optimization Design of Cross Beams Structure

2014 ◽  
Vol 8 (1) ◽  
pp. 117-123
Author(s):  
Ke Zhang ◽  
Xuan Mu ◽  
Dehong Zhao ◽  
Yuhou Wu
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Simulation Analysis ◽  
Lightweight Design ◽  
Optimization Method ◽  
Production Costs ◽  
Structure Quality ◽  
Machining Center ◽  
Traditional Structure ◽  
Inherent Frequency

Solid Isotropic Microstructure with Penalization(SIMP) in topology optimization was deeply analyzed, and thus SIMP topology optimization criteria algorithm was deduced. Simulation analysis to the results was also conducted by Ansys, so as the structural lightweight design to machine crossbeams of the HTM series gantry. By verifying, the structure was 3.8% lower than the traditional structure quality, stiffness increased by 16.07%, and the overall inherent frequency was improved. By applying topology optimization method to the design process of the machining center HTM series, ma-terial utilization is improved and production costs were reduced.

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 Correction to: From Topology Optimization Design to Additive Manufacturing: Today’s Success and Tomorrow’s Roadmap

2020 ◽  
Vol 28 (1) ◽  
pp. 269-269
Author(s):  
Liang Meng ◽  
Weihong Zhang ◽  
Dongliang Quan ◽  
Guanghui Shi ◽  
Lei Tang ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Design

Topological Optimization Design of Top Beam of the Longmen Milling Machine Based on Hyperworks

2013 ◽  
Vol 378 ◽  
pp. 65-68
Author(s):  
Ning Jia ◽  
Fu Yun Liu ◽  
Yun Ze Yang ◽  
Lin Gan ◽  
Qing Qing Chang
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Optimal Allocation ◽  
Volume Fraction ◽  
Lightweight Design ◽  
Topological Optimization ◽  
Design Domain ◽  
Milling Machine ◽  
Optimal Distribution ◽  
Design Variables

Topology optimization is a kind of optimized method, which can seek for an optimal allocation of structural material according to the load,constraints and optimization goals .To achieve the lightweight design of the top beam, establishing a minimum strain as the objective function, the volume fraction as the constraint conditions, and the density of design domain as the design variables,implementing the topology optimization for the top beam,the optimal distribution of top beam material is obtained, which provide a basis for the manufacture of top beam.

The Topological Optimization Design of Cross Beams Structure of Shaped Stone Turning-Milling CNC (HTM50200)

2013 ◽  
Vol 694-697 ◽  
pp. 2725-2728
Author(s):  
Xuan Mu ◽  
Ke Zhang ◽  
De Hong Zhao ◽  
Yu Hou Wu
Keyword(s):  
Topology Optimization ◽  
Machine Tools ◽  
Optimization Design ◽  
Lightweight Design ◽  
Optimization Method ◽  
Production Costs ◽  
Topological Optimization ◽  
Maximum Deformation ◽  
Machining Center ◽  
Traditional Structure

To reduce the overall mass of the machine tools, this paper made the structural lightweight design to crossbeams of the HTM series gantry machine by topology optimization. The topology optimization mathematical model was built by taking the quality as the constraint, overall stiffness to the maximum (complicance to the minimum) as the design goals. It also took HTM50200 Turning Milling Center as an example, put forward an asymmetric layout structure of auxiliary hole according to the optimization results by numerical simulation and calculation of ANSYS. By verified, the mass of the structure was 2.76% lower than traditional structure, and the maximum deformation decreased by 16.07%. By applying the topology optimization method to the design process of the HTM series machining center, the utilization of materials will be improved and the production costs will be reduced.

Based on Topology Optimization Method the Cab Mount Bracket Lightweight Design

2012 ◽  
Vol 152-154 ◽  
pp. 1292-1297 ◽  
Author(s):  
Xin Li ◽  
Li Wang
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Lightweight Design ◽  
Optimization Method ◽  
Optimization Techniques ◽  
Operational Performance ◽  
Comparison Analysis ◽  
Structure Quality ◽  
Performance Requirement ◽  
Hyper Works

Abstract. Truck cab mounting bracket is one of very important connecting elements. With the aid of Hyper Works software topology optimization and shape optimization techniques, the article elaborates that after realizing the cab mount bracket, the suspension support reduces weight leading to optimization design of the process. Meanwhile, it unifies the actual stress situation which has made the finite element validation comparison analysis comparing traditional optimization with the topology optimization design. The final results indicate that after weight loss optimized stent significantly reduce stress and the stress distribution is evener. Also, the relatively primary structure quality has obvious reduction which could satisfy the product the operational performance and the foundry technique performance requirement.

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