Design of a double-optimized lattice structure using the solid isotropic material with penalization method and material extrusion additive manufacturing

2020 ◽  
Vol 234 (17) ◽  
pp. 3447-3458
Author(s):  
Han-Wool Kim ◽  
Young-Seong Kim ◽  
Joong Yeon Lim
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Isotropic Material ◽  
Lattice Structure ◽  
Bending Test ◽  
Penalization Method ◽  
Three Point Bending ◽  
Material Extrusion ◽  
Low Weight ◽  
Penalty Factor

The development of additive manufacturing technology has facilitated the production of cellular structures such as lattices. Topology optimization is a tool for computing the optimal geometry of an object within certain conditions, and it can be used to increase the stiffness and decrease the weight. In this study, a “double-optimized lattice structure” was designed by applying the solid isotropic material with penalization method for topology optimization twice, first to optimize the unit cell of the lattice and then to grade and insert the cells into a global model. This design was applied to a Messerschmitt–Bölkow–Blohm beam and produced via material extrusion additive manufacturing. Subsequently, it was evaluated by a three-point bending test, and the results indicated that the double-optimized lattice beam had a 1.6–1.9 fold greater effective stiffness and a 2 fold higher ultimate load than the values obtained for the beam designed with conventional methods. Thus, the double-optimized lattice structure developed herein can be an effective material with regard to its low weight and high stiffness. Contrarily, the penalty factor p of the solid isotropic material with penalization did not affect the properties. This finding suggests that p can control homogeneity while maintaining the strength of the structure.

scholarly journals Additive Manufacturing-Based In Situ Consolidation of Continuous Carbon Fibre-Reinforced Polycarbonate

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2450
Author(s):  
Andreas Borowski ◽  
Christian Vogel ◽  
Thomas Behnisch ◽  
Vinzenz Geske ◽  
Maik Gude ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fibre ◽  
Bending Test ◽  
Thermoplastic Composites ◽  
Experimental Investigations ◽  
Material Structure ◽  
Three Point Bending ◽  
Continuous Fibre ◽  
Local Material

Continuous carbon fibre-reinforced thermoplastic composites have convincing anisotropic properties, which can be used to strengthen structural components in a local, variable and efficient way. In this study, an additive manufacturing (AM) process is introduced to fabricate in situ consolidated continuous fibre-reinforced polycarbonate. Specimens with three different nozzle temperatures were in situ consolidated and tested in a three-point bending test. Computed tomography (CT) is used for a detailed analysis of the local material structure and resulting material porosity, thus the results can be put into context with process parameters. In addition, a highly curved test structure was fabricated that demonstrates the limits of the process and dependent fibre strand folding behaviours. These experimental investigations present the potential and the challenges of additive manufacturing-based in situ consolidated continuous fibre-reinforced polycarbonate.

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.

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.

Experimental Investigation on Mechanical Property of Hybrid Steel-to-Lattice Joint With Pyramidal Carbon Fiber Truss

2015 ◽  
Author(s):  
Xiongliang Yao ◽  
Wei Wang ◽  
Nana Yang ◽  
Zhanyi Guo
Keyword(s):  
Mechanical Property ◽  
Carbon Fiber ◽  
Lattice Structure ◽  
Bending Test ◽  
Face Sheet ◽  
Three Point Bending ◽  
Specific Strength ◽  
Composite Sandwich ◽  
Hybrid Joint ◽  
Lattice Core

As a novel type of composite sandwich structure in recent years lattice structure with carbon fiber pyramidal truss core is applied to warship’s superstructure because of its high specific stiffness and specific strength, but it is difficult to design joint between superstructure and hull and there are few researches about the mechanical property of hybrid steel-to-lattice joint. Two kinds of hybrid joint specimens are designed and their compressive and flexural properties are investigated. The experimental results show that in compression test lattice sandwich is weakest and that debonding resulted from core macro-shear and face sheet wrinkling can lead to overall instability; bearing reaction can result in resin base fracture in lattice core and face sheet delamination is the main damage mode of joint structure in three-point bending test, which happens where stiffness mutation appears.

Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints

2020 ◽  
pp. 095440622091771
Author(s):  
Sara Mantovani ◽  
Giuseppe A Campo ◽  
Andrea Ferrari
Keyword(s):  
Finite Element ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Isotropic Material ◽  
Element Model ◽  
The Body ◽  
Left Hand ◽  
Automotive Body ◽  
Body In White ◽  
Overhang Angle

In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is in the front area of the Body-in-White, between the left-hand-side shock-tower and the Cross Car Beam, and its task is to support the steering column. The dash under investigation is an asymmetric rib-web aluminium casting part. The influence of Additive Manufacturing constraints together with modal and stiffness targets is investigated in view of mass reduction. The constraints drive the topology result towards a feasible and fully self-supporting Additive Manufacturing solution. A simplified finite element model of the steering column and of the Body-in-White front area is presented, and the limiting assumption of isotropic material for Additive Manufacturing is discussed. The optimization problem is solved with a gradient-based method relying on the Solid Isotropic Material with Penalization and on the RAtional Material with Penalization algorithms, considering the overhang angle constraint with given build directions. Three metals are tested: steel, aluminium and magnesium alloys. Topology optimization results with and without overhang angle constraints are discussed and compared. The aluminium solution, preferred for its lesser weight, has been preliminarily redesigned following the optimization results. The new dash concept has been validated by finite element considering stiffness, modal responses, and buckling resistance targets. The proposed dash design weighs 721 g compared to the 1537 g of the reference dash, with a weight reduction of 53%, for the same structural targets.

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