scholarly journals Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

2021 ◽  
Vol 11 (4) ◽  
pp. 1437
Author(s):  
Evangelos Tyflopoulos ◽  
Mathias Lien ◽  
Martin Steinert
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Procedure ◽  
Optimization Approach ◽  
Design Flexibility ◽  
Current State ◽  
3D Printed ◽  
Removal Processes ◽  
Material Layout

The weight optimization of a structure can be conducted by using fewer and downsized components, applying lighter materials in production, and removing unwanted material. Topology optimization (TO) is one of the most implemented material removal processes. In addition, when it is oriented towards additive manufacturing (AM), it increases design flexibility. The traditional optimization approach is the compliance optimization, where the material layout of a structure is optimized by minimizing its overall compliance. However, TO, in its current state of the art, is mainly used for design inspiration and not for manufacturing due to design complexities and lack of accuracy of its design solutions. The authors, in this research paper, explore the benefits and the limitations of the TO using as a case study the housings of a front and a rear brake caliper. The calipers were optimized for weight reduction by implementing the aforementioned optimization procedure. Their housings were topologically optimized, partially redesigned, prepared for 3D printing, validated, and 3D printed in titanium using selective laser melting (SLM). The weight of the optimized calipers reduced by 41.6% compared to commercial calipers. Designers interested in either TO or in automotive engineering can exploit the findings in this paper.

scholarly journals Level Set Topology Optimization of Printed Active Composites

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Kurt Maute ◽  
Anton Tkachuk ◽  
Jiangtao Wu ◽  
H. Jerry Qi ◽  
Zhen Ding ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Shape Memory ◽  
Level Set ◽  
Spatial Arrangement ◽  
Optimization Method ◽  
Optimization Approach ◽  
Target Shape ◽  
3D Printed ◽  
Residual Strains ◽  
Material Layout

Multimaterial polymer printers allow the placement of different material phases within a composite, where some or all of the materials may exhibit an active response. Utilizing the shape memory (SM) behavior of at least one of the material phases, active composites can be three-dimensional (3D) printed such that they deform from an initially flat plate into a curved structure. This paper introduces a topology optimization approach for finding the spatial arrangement of shape memory polymers (SMPs) within a passive matrix such that the composite assumes a target shape. The optimization approach combines a level set method (LSM) for describing the material layout and a generalized formulation of the extended finite-element method (XFEM) for predicting the response of the printed active composite (PAC). This combination of methods yields optimization results that can be directly printed without the need for additional postprocessing steps. Two multiphysics PAC models are introduced to describe the response of the composite. The models differ in the level of accuracy in approximating the residual strains generated by a thermomechanical programing process. Comparing XFEM predictions of the two PAC models against experimental results suggests that the models are sufficiently accurate for design purposes. The proposed optimization method is studied with examples where the target shapes correspond to a plate-bending type deformation and to a localized deformation. The optimized designs are 3D printed and the XFEM predictions are compared against experimental measurements. The design studies demonstrate the ability of the proposed optimization method to yield a crisp and highly resolved description of the optimized material layout that can be realized by 3D printing. As the complexity of the target shape increases, the optimal spatial arrangement of the material phases becomes less intuitive, highlighting the advantages of the proposed optimization method.

Topology Optimization Software for Additive Manufacturing: A Review of Current Capabilities and a Real-World Example

2016 ◽  
Author(s):  
Sai Nithin Reddy K. ◽  
Ian Ferguson ◽  
Mary Frecker ◽  
Timothy W. Simpson ◽  
Corey J. Dickman
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
User Interfaces ◽  
Educational Software ◽  
Software Tools ◽  
Additive Manufacture ◽  
Optimization Software ◽  
Current State ◽  
Complex Organic

Topology optimization is finding renewed interest thanks to additive manufacturing — a technology that is well-suited to fabricate the complex organic shapes and structures that often arise from topology optimization. This paper reviews the current state of topology optimization software through the redesign of a real aerospace mounting plate, focusing on manufacturing considerations that are important for additive manufacturing (AM). Twenty different commercial and educational software tools are investigated and categorized based on their capabilities. Two representative software tools are then demonstrated with well-known examples to compare user interfaces and outputs, and one is chosen to perform the mounting plate case study. We find that all of the commercially available topology optimization software packages offer similar capabilities and considerably more functionality than educational software, but only a few niche products can be tailored to specific applications and manufacturing processes. Current commercial software does not provide adequate manufacturing constraints to remove the need for manual interpretation of results for additive manufacture. A case study involving optimization of an industry-relevant component for AM is used to provide in-depth understanding of both topology optimization and manufacturing considerations in AM. Shortcomings in the existing software tools are presented, and future requirements to take advantage of the increasing AM capabilities, particularly in metals, are discussed.

Boundary Slope Control in Topology Optimization for Additive Manufacturing: For Self-Support and Surface Roughness

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Cunfu Wang ◽  
Xiaoping Qian ◽  
William D. Gerstler ◽  
Jeff Shubrooks
Keyword(s):  
Heat Transfer ◽  
Surface Roughness ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Density Gradient ◽  
Transfer Efficiency ◽  
Global Constraints ◽  
Optimization Approach ◽  
Heat Transfer Efficiency ◽  
Boundary Slope

This paper studies how to control boundary slope of optimized parts in density-based topology optimization for additive manufacturing (AM). Boundary slope of a part affects the amount of support structure required during its fabrication by additive processes. Boundary slope also has a direct relation with the resulting surface roughness from the AM processes, which in turn affects the heat transfer efficiency. By constraining the minimal boundary slope, support structures can be eliminated or reduced for AM, and thus, material and postprocessing costs are reduced; by constraining the maximal boundary slope, high-surface roughness can be attained, and thus, the heat transfer efficiency is increased. In this paper, the boundary slope is controlled through a constraint between the density gradient and the given build direction. This allows us to explicitly control the boundary slope through density gradient in the density-based topology optimization approach. We control the boundary slope through two single global constraints. An adaptive scheme is also proposed to select the thresholds of these two boundary slope constraints. Numerical examples of linear elastic problem, heat conduction problem, and thermoelastic problems demonstrate the effectiveness and efficiency of the proposed formulation in controlling boundary slopes for additive manufacturing. Experimental results from metal 3D printed parts confirm that our boundary slope-based formulation is effective for controlling part self-support during printing and for affecting surface roughness of the printed parts.

scholarly journals 3D-printed valves to assist noninvasive ventilation procedures during the COVID-19 pandemic: a case study

2020 ◽  
Vol 4 (4) ◽  
pp. 193-202
Author(s):  
Guilherme Arthur Longhitano ◽  
Geovany Candido ◽  
Leonardo Mendes Ribeiro Machado ◽  
Paulo Inforçatti Neto ◽  
Marcelo Fernandes de Oliveira ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Noninvasive Ventilation ◽  
Selective Laser Sintering ◽  
Air Leakage ◽  
Final Model ◽  
Air Contamination ◽  
Sintering Additive ◽  
3D Printed ◽  
Full Face

Aim: To produce valves to be used with full-face snorkeling masks for noninvasive ventilation (NIV) procedure during the coronavirus disease 2019 (COVID-19) pandemic. Materials & methods: ISINNOVA’s Charlotte valves for full-face snorkeling masks used for NIV procedures were redesigned, produced by selective laser sintering additive manufacturing, and submitted to air leakage tests. Results: The final model assembly did not present air leakage during the NIV procedure on human models, minimizing risks of air contamination. Conclusion: This study shows the feasibility of using additive manufactured valves with snorkel facial masks to support health systems during COVID-19 and possible future pandemics.

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 Continuous Fiber Angle Topology Optimization for Polymer Composite Deposition Additive Manufacturing Applications

Fibers ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 14 ◽  
Author(s):  
Delin Jiang ◽  
Robert Hoglund ◽  
Douglas Smith
Keyword(s):  
Mechanical Properties ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polymer Composite ◽  
Fiber Reinforcement ◽  
Fiber Direction ◽  
Optimization Approach ◽  
Continuous Fiber ◽  
Fiber Angle

Mechanical properties of parts produced with polymer deposition additive manufacturing (AM) depend on the print bead direction, particularly when short carbon-fiber reinforcement is added to the polymer feedstock. This offers a unique opportunity in the design of these structures since the AM print path can potentially be defined in a direction that takes advantage of the enhanced stiffness gained in the bead and, therefore, fiber direction. This paper presents a topology optimization approach for continuous fiber angle optimization (CFAO), which computes the best layout and orientation of fiber reinforcement for AM structures. Statically loaded structures are designed for minimum compliance where the adjoint variable method is used to compute design derivatives, and a sensitivity filter is employed to reduce the checkerboard effect. The nature of the layer-by-layer approach in AM is given special consideration in the algorithm presented. Examples are provided to demonstrate the applicability of the method in both two and three dimensions. The solution to our two dimensional problem is then printed with a fused filament fabrication (FFF) desktop printer using the material distribution results and a simple infill method which approximates the optimal fiber angle results using a contour-parallel deposition strategy. Mechanical stiffness testing of the printed parts shows improved results as compared to structures designed without accounting for the direction of the composite structure. Results show that the mechanical properties of the final FFF carbon fiber/polymer composite printed parts are greatly influenced by the print direction, and optimized material orientation tends to align with the imposed force direction to minimize the compliance.

A Multi-Scale Topology Optimization Approach for Optimal Macro-Layout and Local Grading of TPMS-Based Lattices

2021 ◽  
Author(s):  
Niclas Strömberg
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Local Density ◽  
Bulk Material ◽  
Transversely Isotropic ◽  
Benchmark Problems ◽  
Optimization Approach ◽  
Lattice Structures ◽  
Efficient Design ◽  
Multi Scale

Abstract The use of lattice structures in design for additive manufacturing has quickly emerged as a popular and efficient design alternative for creating innovative multifunctional lightweight solutions. In particular, the family of triply periodic minimal surfaces (TPMS) studied in detail by Schoen for generating frame-or shell-based lattice structures seems extra promising. In this paper a multi-scale topology optimization approach for optimal macro-layout and local grading of TPMS-based lattice structures is presented. The approach is formulated using two different density fields, one for identifying the macro-layout and another one for setting the local grading of the TPMS-based lattice. The macro density variable is governed by the standard SIMP formulation, but the local one defines the orthotropic elasticity of the element following material interpolation laws derived by numerical homogenization. Such laws are derived for frame- and shell-based Gyroid, G-prime and Schwarz-D lattices using transversely isotropic elasticity for the bulk material. A nice feature of the approach is that the lower and upper additive manufacturing limits on the local density of the TMPS-based lattices are included properly. The performance of the approach is excellent, and this is demonstrated by solving several three-dimensional benchmark problems, e.g., the optimal macro-layout and local grading of Schwarz-D lattice for the established GE-bracket is identified using the presented approach.

scholarly journals An Open Source Framework for Integrated Additive Manufacturing and Level-Set-Based Topology Optimization

2017 ◽  
Vol 17 (4) ◽  
Author(s):  
Panagiotis Vogiatzis ◽  
Shikui Chen ◽  
Chi Zhou
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Open Source ◽  
Level Set ◽  
Optimization Procedure ◽  
Computational Design ◽  
Standard Format ◽  
Practical Algorithms ◽  
Open Source Framework

Topology optimization has been considered as a promising tool for conceptual design due to its capability of generating innovative design candidates without depending on the designer's intuition and experience. Various optimization methods have been developed through the years, and one of the promising options is the level-set-based topology optimization method. The benefit of this alternative method is that the design is characterized by its clear boundaries. This advantage can avoid postprocessing work in conventional topology optimization process to a large extent and realize direct integration between topology optimization and additive manufacturing (AM). In this paper, practical algorithms and a matlab-based open source framework are developed to seamlessly integrate the level-set-based topology optimization procedure with AM process by converting the design to STereoLithography (STL) files, which is the de facto standard format for three-dimensional (3D) printing. The proposed algorithm and code are evaluated by a proof-of-concept demonstration with 3D printing of both single and multimaterial topology optimization results. The algorithm and the open source framework proposed in this paper will be beneficial to the areas of computational design and AM.

Topology Optimization of Self-Supported Enclosed Voids for Additive Manufacturing

2021 ◽  
Author(s):  
Cunfu Wang
Keyword(s):  
Heat Flux ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Heat Conduction Problem ◽  
Boundary Representation ◽  
Maximum Temperature ◽  
Optimization Approach ◽  
Optimized Design ◽  
Surface Slope ◽  
Conductive Materials

Abstract The paper proposes a heat-flux based topology optimization approach to design self-supported enclosed voids for additive manufacturing. The enclosed overhangs that require supports in additive manufacturing are removed from the optimized design by constraining the maximum temperature of a pseudo heat conduction problem. In the pseudo problem, heat flux is applied on the non-self-supported open and enclosed surfaces. Since the density-based topology optimization involves no explicit boundary representation, we impose such surface slope dependent heat flux through a domain integral of a Heaviside projected density gradient. In addition, the solid materials and the void materials in the pseudo problem are assumed to be thermally insulating and conductive, respectively. As such, heat flux on the open surfaces can be successfully conducted to external heat sink through the void (or conductive) materials. However, heat flux on the non-self-supported enclosed surfaces is isolated by the solid (or insulating) materials and thus leads to locally high temperature. Hence, by limiting the maximum temperature of the pseudo problem, self-supported enclosed voids can be achieved, and the slope of the open surfaces would not be affected. Numerical examples are presented to demonstrate the validity and effectiveness of the proposed approach in the design of self-supported enclosed voids.

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