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.

An improved lattice structure design optimization framework considering additive manufacturing constraints

2017 ◽  
Vol 23 (2) ◽  
pp. 305-319 ◽  
Author(s):  
Recep M. Gorguluarslan ◽  
Umesh N. Gandhi ◽  
Yuyang Song ◽  
Seung-Kyum Choi
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structure ◽  
Structure Optimization ◽  
Optimization Methods ◽  
Structure Design ◽  
Second Phase ◽  
Manufacturing Constraints ◽  
Ground Structure ◽  
Content Type ◽  
Optimization Framework

Purpose Methods to optimize lattice structure design, such as ground structure optimization, have been shown to be useful when generating efficient design concepts with complex truss-like cellular structures. Unfortunately, designs suggested by lattice structure optimization methods are often infeasible because the obtained cross-sectional parameter values cannot be fabricated by additive manufacturing (AM) processes, and it is often very difficult to transform a design proposal into one that can be additively designed. This paper aims to propose an improved, two-phase lattice structure optimization framework that considers manufacturing constraints for the AM process. Design/methodology/approach The proposed framework uses a conventional ground structure optimization method in the first phase. In the second phase, the results from the ground structure optimization are modified according to the pre-determined manufacturing constraints using a second optimization procedure. To decrease the computational cost of the optimization process, an efficient gradient-based optimization algorithm, namely, the method of feasible directions (MFDs), is integrated into this framework. The developed framework is applied to three different design examples. The efficacy of the framework is compared to that of existing lattice structure optimization methods. Findings The proposed optimization framework provided designs more efficiently and with better performance than the existing optimization methods. Practical implications The proposed framework can be used effectively for optimizing complex lattice-based structures. Originality/value An improved optimization framework that efficiently considers the AM constraints was reported for the design of lattice-based structures.

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

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.

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.

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

scholarly journals Toward the integration of lattice structure-based topology optimization and additive manufacturing for the design of turbomachinery components

2019 ◽  
Vol 11 (8) ◽  
pp. 168781401985978
Author(s):  
Enrico Boccini ◽  
Rocco Furferi ◽  
Lapo Governi ◽  
Enrico Meli ◽  
Alessandro Ridolfi ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Three Dimensional ◽  
Optimization Method ◽  
Lattice Structures ◽  
Stiffness Properties ◽  
Maximum Stiffness ◽  
Layer Manufacturing ◽  
Innovative Materials

Used in several industrial fields to create innovative designs, topology optimization is a method to design a structure characterized by maximum stiffness properties and reduced weights. By integrating topology optimization with additive layer manufacturing and, at the same time, by using innovative materials such as lattice structures, it is possible to realize complex three-dimensional geometries unthinkable using traditional subtractive techniques. Surprisingly, the extraordinary potential of topology optimization method (especially when coupled with additive manufacturing and lattice structures) has not yet been extensively developed to study rotating machines. Based on the above considerations, the applicability of topology optimization, additive manufacturing, and lattice structures to the fields of turbomachinery and rotordynamics is here explored. Such techniques are applied to a turbine disk to optimize its performance in terms of resonance and mass reduction. The obtained results are quite encouraging since this approach allows improving existing turbomachinery components’ performance when compared with traditional one.

scholarly journals Design of Variable-Density Structures for Additive Manufacturing Using Gyroid Lattices

2017 ◽  
Author(s):  
Botao Zhang ◽  
Kunal Mhapsekar ◽  
Sam Anand
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Volume Fraction ◽  
Complex Geometry ◽  
Lattice Structure ◽  
Variable Density ◽  
Light Weight ◽  
Lattice Structures ◽  
Density Mapping ◽  
Usage Cost

Additive manufacturing (AM) processes enable the creation of lattice structures having complex geometry which offer great potential for designing light weight parts. The combination of AM and cellular lattice structures provide promising design solutions in terms of material usage, cost and part weight. However, the geometric complexity of the structures calls for a robust methodology to incorporate the lattices in parts designs and create optimum light weight designs. This paper proposes a novel method for designing light weight variable-density lattice structures using gyroids. The parametric 3D implicit function of gyroids has been used to control the shape and volume fraction of the lattice. The proposed method is then combined with the density distribution information from topology optimization algorithm. A density mapping and interpolation approach is proposed to map the output of topology optimization into the parametric gyroids structures which results in an optimum lightweight lattice structure with uniformly varying densities across the design space. The proposed methodology has been validated with two test cases.

Static Design Based on Hierarchy Optimization Associating Materials and Structures

2011 ◽  
Vol 287-290 ◽  
pp. 544-547
Author(s):  
Yuan Dong Liu ◽  
Yi Hui Yin ◽  
Ying Chun Lu
Keyword(s):  
Topology Optimization ◽  
Porous Material ◽  
Numerical Experiments ◽  
Optimization Design ◽  
Integrated Design ◽  
Material Design ◽  
Structure Design ◽  
Design Model ◽  
Numerical Examples ◽  
Design Structure

In order to study the comparison of material design, structure design and integrated design about the porous material, a concurrent topology optimization design model associating materials and structures with periodical microstructures is presented. The sensitivity formulae of hierarchy optimization are given based on the integrated design model and related numerical experiments were carried out. The applicability of hierarchy optimization is discussed and their advantage and disadvantage are analyzed through numerical examples which provide some useful opinions about the porous material design.

scholarly journals Optimization Approaches in Design for Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 809-818
Author(s):  
Stefano Rosso ◽  
Gianpaolo Savio ◽  
Federico Uriati ◽  
Roberto Meneghello ◽  
Gianmaria Concheri
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Geometric Modeling ◽  
Lattice Structure ◽  
Software Tool ◽  
Lattice Structures ◽  
Commercial Software ◽  
Lightweight Structure ◽  
Sharp Edges ◽  
Manufacturing Technologies

AbstractNowadays, topology optimization and lattice structures are being re-discovered thanks to Additive Manufacturing technologies, that allow to easily produce parts with complex geometries.The primary aim of this work is to provide an original contribution for geometric modeling of conformal lattice structures for both wireframe and mesh models, improving previously presented methods. The secondary aim is to compare the proposed approaches with commercial software solutions on a piston rod as a case study.The central part of the rod undergoes size optimization of conformal lattice structure beams diameters using the proposed methods, and topology optimization using commercial software tool. The optimized lattice is modeled with a NURBS approach and with the novel mesh approach, while the topologically optimized part is manually remodeled to obtain a proper geometry. Results show that the lattice mesh modelling approach has the best performance, resulting in a lightweight structure with smooth surfaces and without sharp edges at nodes, enhancing mechanical properties and fatigue life.

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