Study on Topology Optimization Design, Manufacturability, and Performance Evaluation of Ti-6Al-4V Porous Structures Fabricated by Selective Laser Melting (SLM)

Purpose This paper aims to summarize design rules based on the process characteristics of selective laser melting (SLM) and structural optimization and apply the design rules in the lightweight design of an aluminum alloy antenna bracket. The design goal is to reduce 30 per cent of the weight while maintaining the stress levels in the original part. Design/methodology/approach To reduce weight as much as possible, the titanium alloy with higher specific strength was selected during the process of optimization. The material distribution of the bracket was improved by the topology optimization design. The redesign for SLM was used to obtain an optimization model, which was more suitable for SLM. The component performance was improved by shape optimization. The modal analysis data of the structural optimization model were compared with those of the stochastic lightweight model to verify the structural optimization model. The scanning data were compared with those of the original model to verify whether the model was suitable for SLM. Findings Structural optimization design for antenna bracket realized the mass decrease of 30.43 per cent and the fundamental frequency increase of 50.18 per cent. The modal analysis data of the stochastic lightweight model and the structural optimization model indicated that the optimization performance of structural optimization method was better than that of the stochastic lightweight method. The comparison results between the scanning data of the forming part and the original data confirmed that the structural optimization design for SLM lightweight component could achieve the desired forming accuracy. Originality/value This paper summarizes geometric constraints in SLM and derives design rules of structural optimization based on the process characteristics of SLM. SLM design rules make structural optimization design more reasonable. The combination of structural optimization design and SLM can improve the performance of lightweight antenna bracket significantly.

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Novel Ti-Based Nanocomposites by Selective Laser Melting (SLM) Additive Manufacturing (AM): Tailored Nanostructure and Performance

Laser Additive Manufacturing of High-Performance Materials ◽

10.1007/978-3-662-46089-4_3 ◽

2015 ◽

pp. 73-113

Author(s):

Dongdong Gu

Keyword(s):

Additive Manufacturing ◽

Selective Laser Melting ◽

Laser Melting ◽

And Performance

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Generation of graded porous structures by control of process parameters in the selective laser melting of a fixed ratio salt-metal feedstock

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2020.04.039 ◽

2020 ◽

Vol 55 ◽

pp. 249-253

Author(s):

Nesma T. Aboulkhair ◽

Ge Zhao ◽

Richard J.M. Hague ◽

Andrew R. Kennedy ◽

Ian A. Ashcroft ◽

...

Keyword(s):

Selective Laser Melting ◽

Process Parameters ◽

Fixed Ratio ◽

Porous Structures ◽

Laser Melting

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Pulsed mode selective laser melting of porous structures: Structural and thermophysical characterization

Additive Manufacturing ◽

10.1016/j.addma.2020.101263 ◽

2020 ◽

Vol 35 ◽

pp. 101263 ◽

Cited By ~ 1

Author(s):

Davoud Jafari ◽

Wessel W. Wits ◽

Tom H.J. Vaneker ◽

Ali Gökhan Demir ◽

Barbara Previtali ◽

...

Keyword(s):

Selective Laser Melting ◽

Porous Structures ◽

Laser Melting ◽

Pulsed Mode ◽

Thermophysical Characterization

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Manufacturability of superelastic nickel-free porous structures for load-bearing medical implants using the space holder and selective laser melting technologies

Frontiers in Bioengineering and Biotechnology ◽

10.3389/conf.fbioe.2016.01.02112 ◽

2016 ◽

Vol 4 ◽

Author(s):

Brailovski Vladimir ◽

Konopatsky Anton ◽

Kreitcberg Alena ◽

Dubinskiy Sergey ◽

Zhukova Yulia ◽

...

Keyword(s):

Selective Laser Melting ◽

Porous Structures ◽

Medical Implants ◽

Laser Melting ◽

Load Bearing ◽

Space Holder

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Design approaches for additive manufactured components, with a focus on selective laser melting

Rakenteiden Mekaniikka ◽

10.23998/rm.64915 ◽

2017 ◽

Vol 50 (3) ◽

pp. 279-282

Author(s):

Erin Komi ◽

Petteri Kokkonen

Keyword(s):

Selective Laser Melting ◽

3D Model ◽

Layer By Layer ◽

Model Data ◽

Laser Melting ◽

Component Design ◽

Subtractive Manufacturing ◽

Successful Design ◽

Manufacturing Techniques ◽

And Performance

Additive manufacturing (AM) of metal components is characterized by the joining of material particles or feedstock to make parts described by 3D model data in typically a layer by layer fashion [1]. These modern and constantly improving manufacturing techniques inherently allow far more geometric freedom than traditional “subtractive” manufacturing processes, and thus necessitate novel approaches to component design. Careful utilization of this geometric freedom can be translated into products characterized by improved functionality and performance, simplified assemblies, are customizable, and/or lightweight [2-5]. This paper provides a brief overview design approaches, manufacturing limitations, and available tools for successful design of additive manufactured components, with special attention paid to the selective laser melting (SLM) approach.

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