scholarly journals Fatigue Behavior of Metallic Components Obtained by Topology Optimization for Additive Manufacturing

2020 ◽  
Vol 15 (55) ◽  
pp. 119-135
Author(s):  
Felipe Fiorentin ◽  
Bernardo Oliveira ◽  
João Pereira ◽  
José Correia ◽  
Abilio M.P. de Jesus ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Manufacturing Process ◽  
Fatigue Behavior ◽  
Volume Ratio ◽  
Design Solution ◽  
Component Design ◽  
Final Design ◽  
Smoothing Process

The main goal of the present research is to propose an integrated methodology to address the fatigue performance of topology optimized components, produced by additive manufacturing. The main steps of the component design will be presented, specially the methods and parameters applied to the topology optimization and the post-smoothing process. The SIMP method was applied in order to obtain a lighter component and a suitable stiffness for the desired application. In addition, since residual stresses are intrinsic to every metallic additive manufacturing process, the influence of those stresses will be also analyzed. The Laser Powder Bed Fusion was numerically simulated aiming at evaluating the residual stresses the workpiece during the manufacturing process and to investigate how they could influence the fatigue behavior of the optimized component. The effect of the built orientation of the workpiece on the residual stresses at some selected potential critical points are evaluated. The final design solution presented a stiffness/volume ratio nearly 6 times higher when compared to the initial geometry. By choosing the built orientation, it is possible impact favorably in the fatigue life of the component.

scholarly journals Taking into account thermal residual stresses in topology optimization of structures built by additive manufacturing

2018 ◽  
Vol 28 (12) ◽  
pp. 2313-2366 ◽  
Author(s):  
Grégoire Allaire ◽  
Lukas Jakabčin
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Heat Fluxes ◽  
Powder Layer ◽  
Layer By Layer ◽  
Thermal Deformations ◽  
Thermal Residual Stresses ◽  
Structural Design Optimization ◽  
Manufacturing Techniques

We introduce a model and several constraints for shape and topology optimization of structures, built by additive manufacturing techniques. The goal of these constraints is to take into account the thermal residual stresses or the thermal deformations, generated by processes like Selective Laser Melting, right from the beginning of the structural design optimization. In other words, the structure is optimized concurrently for its final use and for its behavior during the layer-by-layer production process. It is well known that metallic additive manufacturing generates very high temperatures and heat fluxes, which in turn yield thermal deformations that may prevent the coating of a new powder layer, or thermal residual stresses that may hinder the mechanical properties of the final design. Our proposed constraints are targeted to avoid these undesired effects. Shape derivatives are computed by an adjoint method and are incorporated into a level set numerical optimization algorithm. Several 2D and 3D numerical examples demonstrate the interest and effectiveness of our approach.

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.

Repeatability of a Topology Optimized Tapered Box Beam Additively Manufactured With Electron Beam Melted Ti-6Al-4V

2020 ◽  
Author(s):  
Eric Bol ◽  
M. Ramulu
Keyword(s):  
Electron Beam ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Aircraft Engine ◽  
Maximum Principal Stress ◽  
Strength Testing ◽  
Commercial Aircraft ◽  
Box Beam ◽  
Maximum Stiffness ◽  
Final Design

Abstract In order for metal additive manufacturing to fully break into the commercial aircraft industry the process has to be stable and repeatable. The product safety of high-quality serial production components is directly related to manufacturing repeatability. In this study a tapered box beam resembling a scaled down commercial aircraft engine pylon forward strut box is designed for additive manufacturing using 3D topology optimization as a guide. The topology optimization algorithm initially sized the structure for maximum stiffness, then the resulting CAD model was redesigned and analyzed for maximum principal stress to reduce the weight. The final design had an asymmetric organic-like truss structure that was manufactured in two halves out of titanium using an Arcam A2X electron beam powder bed fusion machine. A trial build helped to determine the proper support strategy to achieve quality specimens with tight tolerances that would facilitate assembly. To test the manufacturing repeatability a series of three builds was executed to produce six beam specimens for follow-on analysis and strength testing. This paper describes the design, analysis, and manufacturing process for a topology optimized taped box beam that is intended for future ultimate strength testing and analysis.

Topology Optimization for Additive Manufacturing Considering Layer-Based Minimum Feature Sizes

2017 ◽  
Author(s):  
Mikhail Osanov ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Design Tool ◽  
Geometric Constraints ◽  
Layer By Layer ◽  
Simple Modification ◽  
Complex Structural ◽  
Manufacturing Technologies

The rapid advance of additive manufacturing technologies has provided new opportunities for creating complex structural shapes. In order to fully exploit these opportunities, however, engineers must re-think the design process and leverage these new capabilities while respecting manufacturing constraints inherent in various processes. Topology optimization, as a free-from design tool, is a potentially powerful approach to addressing this design challenge provided the manufacturing process is properly accounted for. This work examines geometric constraints related to feature size and the layer-by-layer nature of the manufacturing process. A simple modification to the Heaviside Projection Method, an approach for naturally achieving geometric constraints in topology optimization, is proposed and demonstrated to have clear, understandable impact on three-dimensional optimized beam designs.

scholarly journals Weldment to Casting Conversion Using Topology Optimization

2021 ◽  
Vol 9 (8) ◽  
pp. 1309-1319
Author(s):  
Prasad Kulkarni
Keyword(s):  
Topology Optimization ◽  
Fatigue Life ◽  
Fatigue Strength ◽  
Dimensional Stability ◽  
Manufacturing Process ◽  
Traditional Method ◽  
Design For Manufacturability ◽  
Final Design ◽  
The Cost ◽  
Casting Design

Abstract: The automobile and off highway industries grapple with dilemma of making a required component out of a weldment by welding different plates together or making a single component using a casting manufacturing process. The decision is always based on many parameters viz. volume of manufactured components, tooling cost involved, dimensional stability required, cost of welding, fatigue strength required etc. As the volume of the manufactured components increases, the cost of casting and its tool goes down and hence it makes sense to convert the weldment into a casting. A traditional method to do this is to convert the weldment into a casting based on functionalities and experience. In this paper, a topology optimization based approach is used to understand and decide the most optimal usage of the material based on the different constraints. In this paper, considerations of weldment to casting conversion, usage of topology optimization to arrive at final design and strength and fatigue life calculation are discussed. Keywords: Weldment, Topology Optimization, casting, Design for Manufacturability

Promotion of Knowledge and Technology Transfer Towards Innovative Manufacturing Process: Case Study of New Hybrid Coating Process

2019 ◽  
Vol 13 (3) ◽  
pp. 419-431 ◽  
Author(s):  
Kentaro Shinoda ◽  
Hiroaki Noda ◽  
Koichi Ohtomi ◽  
Takayuki Yamada ◽  
Jun Akedo ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
New Technologies ◽  
Aerosol Deposition ◽  
Design Tool ◽  
Coating Process ◽  
Past Study ◽  
Fine Ceramics

A new, multi-dimensional, additive manufacturing process for fine ceramics was proposed and developed as part of a national project in Japan. The process consists of three-dimensional printing and two-dimensional coating of fine ceramics. A new coating process, hybrid aerosol deposition (HAD), was proposed as the ceramic coating process. The HAD process is a hybrid of aerosol deposition (AD) and plasma spray. Such new technologies, however, usually take a long time to move from first discovery to use in producing a commercial product. For example, a past study showed that it took nearly 15 years from the invention of the AD process to the time it became a technology used at an industrial company. Therefore, it is very important to consider how to accelerate the learning and technological transfer of a new process to industry in addition to how to develop new processes once they emerge. In this study, a new scheme, a coating hub, is proposed to promote the transfer of the HAD process to industrial adoption. In the coating hub, a collaboration scheme for companies to get interest of the technology, even in the early stages of technological development, is considered. Here, needs-seeds matching, reliable relationships, intellectual property, and the generalization of technology are considered. Another important scheme of the coating hub is to try to couple design with manufacturing. Here, product design tools for agile production are provided. In order to attract and evaluate consumers for targeted products, a Kansei delight design based on the Kano model is introduced. A delight map viewer is provided to visualize potential consumers’ delight factors. Detailed planning from the early trial stage is introduced with the viewer. A topology optimization tool is also provided in the coating hub as a design tool. In order to validate this coating hub concept, a ceramic frying pan is designed as a case study. The delight map viewer proves effective for those who are not design professionals to consider the attractiveness of products based on user evaluation. The coupling of the topology optimization tool is also useful for the multidimensional additive manufacturing of ceramics proposed in this study. This case study implies that even a small manufacturer could design a new product by utilizing the coating hub concept. It would give many new opportunities not only to big manufactures interested in high-end business-to-business components but also to supporting industries and even to individuals to utilize new emerging coating technologies.

scholarly journals Topology Optimization by the use of 3D Printing Technology in the Product Design Process

2020 ◽  
Vol 1 (4) ◽  
pp. 161-171
Author(s):  
Ioannis Ntintakis ◽  
Georgios Eleftherios Stavroulakis ◽  
Niki Plakia
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Design Process ◽  
Raw Material ◽  
Design Solution ◽  
Compression Tests ◽  
High Durability ◽  
Optimization Study ◽  
Study Results ◽  
The Right

The designing process of a new product includes various stages, one of which is the evaluation of an idea thought prototype manufacturing. The use of additive manufacturing consists the most efficient and effective way for prototype manufacturing. In order to maximize the benefits from the use of additive manufacturing, we should choose the suitable printing parameters. A vital parameter for defining the quantity of raw material used and the model solidity is the inner wall thickness. Depending on the selected technique of additive manufacturing, the thickness of the inner wall may differ. In this study we initially print furniture models with different wall thicknesses using the Inject Binder technique and then we check their durability and resilience by compression tests. Evaluating the study results indicate the hollow printed specimens have high durability during compression tests and can be used to evaluate a design idea. Using the facts derived from lab tests we perform Topology Optimization studies under different circumstances to evaluate the method and come up with the optimal design solution. Initially, the Topology Optimization study concern only the table surface and not the whole model. The following studies were performed for the whole model, different constraints and load cases defined. Then, the optimized models are redesigned in order to improve their durability. The performed studies show that Topology Optimization is a powerful tool, which is able to support the designers/ engineers to take the right decision during the design process. Doi: 10.28991/HIJ-2020-01-04-03 Full Text: PDF

Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing

2017 ◽  
Author(s):  
Long Jiang ◽  
Hang Ye ◽  
Chi Zhou ◽  
Shikui Chen ◽  
Wenyao Xu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Level Set ◽  
Manufacturing Process ◽  
Rational Design ◽  
Optimization Method ◽  
Significant Advance ◽  
Original Design ◽  
Computational Framework ◽  
Multi Scale

The significant advance in the boosted fabrication speed and printing resolution of additive technology has considerably increased the capability of achieving product designs with high geometric complexity. The prefabrication computation has been increasingly important and is coming to be the bottleneck in the additive manufacturing process. In this paper, the authors devise an integrated computational framework by synthesizing the parametric level set-based topology optimization method with the DLP-based SLA process for intelligent design and additive manufacturing of not only single material structures but also multi-scale, multi-functional structures. The topology of the design is optimized with a new distance-regularized parametric level set method considering the prefabrication computation. offering the flexibility and robustness of the structural design that the conventional methods could not provide. The output of the framework is a set of mask images which can be directly used in the additive manufacturing process. The proposed approach seamlessly integrates the rational design and manufacturing to reduce the complexity of the computationally-expensive prefabrication process. Two test examples, including a freeform 3D cantilever beam and a multi-scale meta-structure, are utilized to demonstrate the performance of the proposed approach. Both the simulation and experimental results verified that the new rational design could significantly reduce the prefabrication computation cost without affecting the original design intent or sacrificing original functionality.

Additively Manufactured Components With Embedded Instrumentation

2016 ◽  
Author(s):  
Matthew Davis ◽  
John Middendorf ◽  
Naman Garg ◽  
Osgar John Ohanian
Keyword(s):  
Additive Manufacturing ◽  
Residual Stresses ◽  
Fiber Optic ◽  
Fiber Reinforced Polymers ◽  
High Definition ◽  
Reinforced Polymers ◽  
Sensing Technology ◽  
Component Design ◽  
Residual Strains ◽  
Printing Processes

Additively manufactured components enable complex structures to be rapidly fabricated and tested for use in the automotive and aerospace industries. Additive manufacturing capabilities have expanded to include a variety of plastics, metal alloys, and fiber-reinforced polymers. There is interest in quantifying the residual stresses in components that have been manufactured using 3D printing processes in order to refine fabrication parameters and improve the performance of component design. Luna Innovations has developed and demonstrated methods to embed high definition fiber optic sensing (HD-FOS) technology into components that have been additively manufactured using ABS plastic as well as a cobalt chrome alloy. This technology enables characterization of internal residual stresses and provides a method for lifetime health monitoring of these printed components using the strain and temperature sensors installed during printing. The sensing technology utilizes the Rayleigh backscatter pattern contained in an optical fiber to determine the strain or temperature, with a high spatial resolution of 1.28 mm, along a fiber that can be embedded inside a printed component. HD-FOS technology was used to measure internal residual strains within layers of varying depths of an ABS printed block, showing a parabolic strain profile with a peak at 9,600 microstrain. In addition to characterizing the printing process, a method has been demonstrated to embed a distributed temperature sensor into a metallic additively manufactured component. This enables the temperature of the part to be measured while it is in use, providing data on the heat transfer through the component. Additive manufacturing has enabled embedding fiber optic sensors in new configurations that were previously unobtainable.

scholarly journals Advances in additive manufacturing process simulation: Residual stresses and distortion predictions in complex metallic components

2020 ◽  
Vol 193 ◽  
pp. 108779 ◽  
Author(s):  
Xu Song ◽  
Stefanie Feih ◽  
Wei Zhai ◽  
Chen-Nan Sun ◽  
Feng Li ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Residual Stresses ◽  
Process Simulation ◽  
Manufacturing Process
Sign in / Sign up

Export Citation Format

Share Document