Using Topology Optimization to Improve Design for Additive Manufacture
Using Topology Optimization to Improve Design for Additive Manufacture

Author: Ian Ferguson

Publisher:

Published: 2015

Total Pages:

ISBN-13:

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Additive manufacturing (AM) offers new design freedom to create topologies with complex surfaces and internal structures that could not be produced by traditional manufacturing processes. Due to this design flexibility, parts designed for AM have the potential to withstand the same structural loads as traditionally manufactured parts at lower masses. In an attempt to reduce the mass of structural parts to a minimum, optimization techniques such as topology optimization can be employed to achieve geometries that may be unintuitive to designers. While in many cases AM is the only means to realize such an optimized design, the constraints of the particular AM process may require a design to be modified before it can be produced. This thesis examines the current state of topology optimization technology and investigates how topology optimization software fits into the workflow of design for AM. This is achieved by exploring the problem of minimizing the mass of a mounting plate for an aerospace vehicle. Optimization is performed with varying boundary conditions and materials to observe their effect on resulting topologies and design performance. The results are then manually interpreted to conform to AM constraints. A 60% weight savings was achieved over the current mounting plate design, but the optimization software did not take AM constraints into account. Manual design modifications were required to ensure that the design was one continuous part and that a suitable prototype of the optimized design could be produced. In the context of this problem, the benefits and limitations of incorporating topology optimization into design for AM are presented. It was found that manual design workflow for AM requires the designer to iterate design around performance, while incorporating topology optimization into the workflow requires the designer to iterate design around manufacturability.

Towards Design Automation for Additive Manufacturing
Towards Design Automation for Additive Manufacturing

Author: Anton Wiberg

Publisher: Linköping University Electronic Press

Published: 2019-10-14

Total Pages: 53

ISBN-13: 9179299857

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In recent decades, the development of computer-controlled manufacturing by adding materiallayer by layer, called Additive Manufacturing (AM), has developed at a rapid pace. The technologyadds possibilities to the manufacturing of geometries that are not possible, or at leastnot economically feasible, to manufacture by more conventional manufacturing methods. AMcomes with the idea that complexity is free, meaning that complex geometries are as expensiveto manufacture as simple geometries. This is partly true, but there remain several design rulesthat needs to be considered before manufacturing. The research field Design for Additive Manufacturing(DfAM) consists of research that aims to take advantage of the possibilities of AMwhile considering the limitations of the technique. Computer Aided technologies (CAx) is the name of the usage of methods and software thataim to support a digital product development process. CAx includes software and methodsfor design, the evaluation of designs, manufacturing support, and other things. The commongoal with all CAx disciplines is to achieve better products at a lower cost and with a shorterdevelopment time. The work presented in this thesis bridges DfAM with CAx with the aim of achieving designautomation for AM. The work reviews the current DfAM process and proposes a new integratedDfAM process that considers the functionality and manufacturing of components. Selectedparts of the proposed process are implemented in a case study in order to evaluate theproposed process. In addition, a tool that supports part of the design process is developed. The proposed design process implements Multidisciplinary Design Optimization (MDO) witha parametric CAD model that is evaluated from functional and manufacturing perspectives. Inthe implementation, a structural component is designed using the MDO framework, which includesComputer Aided Engineering (CAE) models for structural evaluation, the calculation ofweight, and how much support material that needs to be added during manufacturing. Thecomponent is optimized for the reduction of weight and minimization of support material,while the stress levels in the component are constrained. The developed tool uses methodsfor high level Parametric CAD modelling to simplify the creation of parametric CAD modelsbased on Topology Optimization (TO) results. The work concludes that the implementation of CAx technologies in the DfAM process enablesa more automated design process with less manual design iterations than traditional DfAM processes.It also discusses and presents directions for further research to achieve a fully automateddesign process for Additive Manufacturing.

Rapid Manufacturing
Rapid Manufacturing

Author: Neil Hopkinson

Publisher: John Wiley & Sons

Published: 2006-02-22

Total Pages: 304

ISBN-13: 9780470032862

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Rapid Manufacturing is a new area of manufacturing developed from a family of technologies known as Rapid Prototyping. These processes have already had the effect of both improving products and reducing their development time; this in turn resulted in the development of the technology of Rapid Tooling, which implemented Rapid Prototyping techniques to improve its own processes. Rapid Manufacturing has developed as the next stage, in which the need for tooling is eliminated. It has been shown that it is economically feasible to use existing commercial Rapid Prototyping systems to manufacture series parts in quantities of up to 20,000 and customised parts in quantities of hundreds of thousands. This form of manufacturing can be incredibly cost-effective and the process is far more flexible than conventional manufacturing. Rapid Manufacturing: An Industrial Revolution for the Digital Age addresses the academic fundamentals of Rapid Manufacturing as well as focussing on case studies and applications across a wide range of industry sectors. As a technology that allows manufacturers to create products without tools, it enables previously impossible geometries to be made. This book is abundant with images depicting the fantastic array of products that are now being commercially manufactured using these technologies. Includes contributions from leading researchers working at the forefront of industry. Features detailed illustrations throughout. Rapid Manufacturing: An Industrial Revolution for the Digital Age is a groundbreaking text that provides excellent coverage of this fast emerging industry. It will interest manufacturing industry practitioners in research and development, product design and materials science, as well as having a theoretical appeal to researchers and post-graduate students in manufacturing engineering, product design, CAD/CAM and CIFM.

Topology Optimization in Engineering Structure Design
Topology Optimization in Engineering Structure Design

Author: Jihong Zhu

Publisher: Elsevier

Published: 2016-11-08

Total Pages: 296

ISBN-13: 0081021194

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Topology Optimization in Engineering Structure Design explores the recent advances and applications of topology optimization in engineering structures design, with a particular focus on aircraft and aerospace structural systems.To meet the increasingly complex engineering challenges provided by rapid developments in these industries, structural optimization techniques have developed in conjunction with them over the past two decades. The latest methods and theories to improve mechanical performances and save structural weight under static, dynamic and thermal loads are summarized and explained in detail here, in addition to potential applications of topology optimization techniques such as shape preserving design, smart structure design and additive manufacturing.These new design strategies are illustrated by a host of worked examples, which are inspired by real engineering situations, some of which have been applied to practical structure design with significant effects. Written from a forward-looking applied engineering perspective, the authors not only summarize the latest developments in this field of structure design but also provide both theoretical knowledge and a practical guideline. This book should appeal to graduate students, researchers and engineers, in detailing how to use topology optimization methods to improve product design. Combines practical applications and topology optimization methodologies Provides problems inspired by real engineering difficulties Designed to help researchers in universities acquire more engineering requirements

Multiscale Structural Topology Optimization
Multiscale Structural Topology Optimization

Author: Liang Xia

Publisher: Elsevier

Published: 2016-04-27

Total Pages: 186

ISBN-13: 0081011865

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Multiscale Structural Topology Optimization discusses the development of a multiscale design framework for topology optimization of multiscale nonlinear structures. With the intention to alleviate the heavy computational burden of the design framework, the authors present a POD-based adaptive surrogate model for the RVE solutions at the microscopic scale and make a step further towards the design of multiscale elastoviscoplastic structures. Various optimization methods for structural size, shape, and topology designs have been developed and widely employed in engineering applications. Topology optimization has been recognized as one of the most effective tools for least weight and performance design, especially in aeronautics and aerospace engineering. This book focuses on the simultaneous design of both macroscopic structure and microscopic materials. In this model, the material microstructures are optimized in response to the macroscopic solution, which results in the nonlinearity of the equilibrium problem of the interface of the two scales. The authors include a reduce database model from a set of numerical experiments in the space of effective strain. Presents the first attempts towards topology optimization design of nonlinear highly heterogeneous structures Helps with simultaneous design of the topologies of both macroscopic structure and microscopic materials Helps with development of computer codes for the designs of nonlinear structures and of materials with extreme constitutive properties Focuses on the simultaneous design of both macroscopic structure and microscopic materials Includes a reduce database model from a set of numerical experiments in the space of effective strain

3D Printing and Additive Manufacturing Technologies
3D Printing and Additive Manufacturing Technologies

Author: L. Jyothish Kumar

Publisher: Springer

Published: 2018-06-07

Total Pages: 308

ISBN-13: 9811303053

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This book presents a selection of papers on advanced technologies for 3D printing and additive manufacturing, and demonstrates how these technologies have changed the face of direct, digital technologies for the rapid production of models, prototypes and patterns. Because of their wide range of applications, 3D printing and additive manufacturing technologies have sparked a powerful new industrial revolution in the field of manufacturing. The evolution of 3D printing and additive manufacturing technologies has changed design, engineering and manufacturing processes across such diverse industries as consumer products, aerospace, medical devices and automotive engineering. This book will help designers, R&D personnel, and practicing engineers grasp the latest developments in the field of 3D Printing and Additive Manufacturing.

Design for Additive Manufacturing
Design for Additive Manufacturing

Author: Martin Leary

Publisher: Elsevier

Published: 2019-12-03

Total Pages: 358

ISBN-13: 0128168870

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Design for Additive Manufacturing is a complete guide to design tools for the manufacturing requirements of AM and how they can enable the optimization of process and product parameters for the reduction of manufacturing costs and effort. This timely synopsis of state-of-the-art design tools for AM brings the reader right up-to-date on the latest methods from both academia and industry. Tools for both metallic and polymeric AM technologies are presented and critically reviewed, along with their manufacturing attributes. Commercial applications of AM are also explained with case studies from a range of industries, thus demonstrating best-practice in AM design. Covers all the commonly used tools for designing for additive manufacturing, as well as descriptions of important emerging technologies Provides systematic methods for optimizing AM process selection for specific production requirement Addresses design tools for both metallic and polymeric AM technologies Includes commercially relevant case studies that showcase best-practice in AM design, including the biomedical, aerospace, defense and automotive sectors

Topology Optimization for Additive Manufacturing Involving High-Cycle Fatigue
Topology Optimization for Additive Manufacturing Involving High-Cycle Fatigue

Author: Shyam Suresh

Publisher: Linköping University Electronic Press

Published: 2020-05-05

Total Pages: 41

ISBN-13: 9179298508

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Additive Manufacturing (AM) is gaining popularity in aerospace and automotive industries. This is a versatile manufacturing process, where highly complex structures are fabricated and together with topology optimization, a powerful design tool, it shares the property of providing a very large freedom in geometrical form. The main focus of this work is to introduce new developments of Topology Optimization (TO) for metal AM. The thesis consists of two parts. The first part introduces background and theory, where TO and adjoint sensitivity analysis are described. Furthermore, methodology used to identify surface layer and high-cycle fatigue are introduced. In the second part, three papers are appended, where the first paper presents the treatment of surface layer effects, while the second and third papers provide high-cycle fatigue constraint formulations. In Paper I, a TO method is introduced to account for surface layer effects, where different material properties are assigned to bulk and surface regions. In metal AM, the fabricated components in as-built surface conditions significantly affect mechanical properties, particularly fatigue properties. Furthermore, the components are generally in-homogeneous and have different microstructures in bulk regions compared to surface regions. We implement two density filters to account for surface effects, where the width of the surface layer is controlled by the second filter radius. 2-D and 3-D numerical examples are treated, where the structural stiffness is maximized for a limited mass. For Papers II and III, a high-cycle fatigue constraint is implemented in TO. A continuous-time approach is used to predict fatigue-damage. The model uses a moving endurance surface and the development of damage occurs only if the stress state lies outside the endurance surface. The model is applicable not only for isotropic materials (Paper II) but also for transversely isotropic material properties (Paper III). It is capable of handling arbitrary load histories, including non-proportional loads. The anisotropic model is applicable for additive manufacturing processes, where transverse isotropic properties are manifested not only in constitutive elastic response but also in fatigue properties. Two optimization problems are solved: In the first problem the structural mass is minimized subject to a fatigue constraint while the second problem deals with stiffness maximization subjected to a fatigue constraint and mass constraint. Several numerical examples are tested with arbitrary load histories.

Additive Manufacturing of Metals: The Technology, Materials, Design and Production
Additive Manufacturing of Metals: The Technology, Materials, Design and Production

Author: Li Yang

Publisher: Springer

Published: 2017-05-11

Total Pages: 172

ISBN-13: 3319551280

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This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners

Evolutionary Topology Optimization of Continuum Structures
Evolutionary Topology Optimization of Continuum Structures

Author: Xiaodong Huang

Publisher: John Wiley & Sons

Published: 2010-03-11

Total Pages: 240

ISBN-13: 9780470689479

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Evolutionary Topology Optimization of Continuum Structures treads new ground with a comprehensive study on the techniques and applications of evolutionary structural optimization (ESO) and its later version bi-directional ESO (BESO) methods. Since the ESO method was first introduced by Xie and Steven in 1992 and the publication of their well-known book Evolutionary Structural Optimization in 1997, there have been significant improvements in the techniques as well as important practical applications. The authors present these developments, illustrated by numerous interesting and detailed examples. They clearly demonstrate that the evolutionary structural optimization method is an effective approach capable of solving a wide range of topology optimization problems, including structures with geometrical and material nonlinearities, energy absorbing devices, periodical structures, bridges and buildings. Presents latest developments and applications in this increasingly popular & maturing optimization approach for engineers and architects; Authored by leading researchers in the field who have been working in the area of ESO and BESO developments since their conception; Includes a number of test problems for students as well as a chapter of case studies that includes several recent practical projects in which the authors have been involved; Accompanied by a website housing ESO/BESO computer programs at http://www.wiley.com/go/huang and test examples, as well as a chapter within the book giving a description and step-by-step instruction on how to use the software package BESO2D. Evolutionary Topology Optimization of Continuum Structures will appeal to researchers and graduate students working in structural design and optimization, and will also be of interest to civil and structural engineers, architects and mechanical engineers involved in creating innovative and efficient structures.