Designing of Topology Optimized Parts for Additive Manufacturing

2019 ◽  
Vol 822 ◽  
pp. 526-533
Author(s):  
Alexey Orlov ◽  
Dmitriy V. Masaylo ◽  
Igor A. Polozov ◽  
Pu Guang Ji
Keyword(s):  
Numerical Simulation ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Strain State ◽  
New Products ◽  
Optimization Method ◽  
Additive Technologies ◽  
Lattice Structures ◽  
Initial Material ◽  
Topology Optimization Method

Due to the additive manufacturing process concept - layered synthesis of products, it becomes necessary to apply new approaches to the design of parts. One of the main tools that need to operate is numerical simulation, capable, with a skilful approach, to give an engineer an integrated procedure to the development of new products. Numerical modeling, in addition to carrying out strength calculations, includes topology optimization and the creation of lattice structures, through which it is possible to create lightweight products. New design meets requirements of strength characteristics. The use of this tool leads to a reduction in the amount of initial material and as a result - cost saving. In this paper, using the bracket as an example, was used the topology optimization method with subsequent redesign. The paper presents the results of calculations of the stress-strain state of the initial and final structures, allowing estimating the possible reduction in the mass of the product and the amount of consumable material in the manufacture of additive technologies.

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 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 A Topology Optimization Method for Stochastic Lattice Structures

2021 ◽  
pp. 235-240
Author(s):  
Filippo Cucinotta ◽  
Marcello Raffaele ◽  
Fabio Salmeri
Keyword(s):  
Topology Optimization ◽  
3D Printing ◽  
Structural Optimization ◽  
High Performance ◽  
Three Dimensional ◽  
Optimization Method ◽  
Lattice Structures ◽  
Low Weight ◽  
Topology Optimization Method

AbstractStochastic lattice structures are very powerful solutions for filling three-dimensional spaces using a generative algorithm. They are suitable for 3D printing and are well appropriate to structural optimization and mass distribution, allowing for high-performance and low-weight structures. The paper shows a method, developed in the Rhino-Grasshopper environment, to distribute lattice structures until a goal is achieved, e.g. the reduction of the weight, the harmonization of the stresses or the limitation of the strain. As case study, a cantilever beam made of Titan alloy, by means of SLS technology has been optimized. The results of the work show the potentiality of the methodology, with a very performing structure and low computational efforts.

Topology optimization method of lattice structures based on a genetic algorithm

2016 ◽  
Vol 16 (3) ◽  
pp. 743-753 ◽  
Author(s):  
Ruo-qiang Feng ◽  
Feng-cheng Liu ◽  
Wei-jia Xu ◽  
Min Ma ◽  
Yang Liu
Keyword(s):  
Genetic Algorithm ◽  
Topology Optimization ◽  
Optimization Method ◽  
Lattice Structures ◽  
Topology Optimization Method

Topology Optimization Taking Into Account Geometrical Constraint of No-Closed Hole for Additive Manufacturing Based on Fictitious Physical Model Concept

2021 ◽  
Author(s):  
Takayuki Yamada ◽  
Yuki Noguchi
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Physical Model ◽  
Optimization Method ◽  
Geometrical Constraint ◽  
The Finite Element Method ◽  
Model Concept ◽  
Optimization Framework ◽  
Proposed Model ◽  
Topology Optimization Method

Abstract This paper proposes a topology optimization method that considers the geometrical constraint of a non-closed hole for additive manufacturing based on the fictitious physical model concept. First, the basic topology optimization concept and level set-based method are introduced. Second, the concept of a fictitious physical model for geometrical constraint in the topology optimization framework is discussed. Then, the model for the geometrical constraint of a non-closed hole for additive manufacturing is proposed. Numerical examples are provided to validate the proposed model. In addition, topology optimization considering this geometrical constraint is formulated, and topology optimization algorithms are constructed using the finite element method. Finally, optimization examples are provided to validate the proposed topology optimization method.

scholarly journals Topology Optimization of Hard-Coating Thin Plate for Maximizing Modal Loss Factors

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 774
Author(s):  
Haitao Luo ◽  
Rong Chen ◽  
Siwei Guo ◽  
Jia Fu
Keyword(s):  
Topology Optimization ◽  
Objective Function ◽  
Composite Plates ◽  
Optimization Method ◽  
Hard Coating ◽  
Design Variables ◽  
Coating Composite ◽  
Damping Materials ◽  
Topology Optimization Method ◽  
Loss Factors

At present, hard coating structures are widely studied as a new passive damping method. Generally, the hard coating material is completely covered on the surface of the thin-walled structure, but the local coverage cannot only achieve better vibration reduction effect, but also save the material and processing costs. In this paper, a topology optimization method for hard coated composite plates is proposed to maximize the modal loss factors. The finite element dynamic model of hard coating composite plate is established. The topology optimization model is established with the energy ratio of hard coating layer to base layer as the objective function and the amount of damping material as the constraint condition. The sensitivity expression of the objective function to the design variables is derived, and the iteration of the design variables is realized by the Method of Moving Asymptote (MMA). Several numerical examples are provided to demonstrate that this method can obtain the optimal layout of damping materials for hard coating composite plates. The results show that the damping materials are mainly distributed in the area where the stored modal strain energy is large, which is consistent with the traditional design method. Finally, based on the numerical results, the experimental study of local hard coating composites plate is carried out. The results show that the topology optimization method can significantly reduce the frequency response amplitude while reducing the amount of damping materials, which shows the feasibility and effectiveness of the method.

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