An Improved Density-Based Design Method of Additive Manufacturing Fabricated Inhomogeneous Cellular-Solid Structures
- 8 Downloads
Benefited from the rapid development of additive manufacturing (AM), inhomogeneous cellular structures have attracted many interests for their superior structural and functional performance. Recently proposed density-based design methods have been shown to provide great computational efficiency and obtain structures with excellent performance. To achieve better structural performance while considering AM constraints, an improved density-based design method which introduces solid and void units into the design domain is proposed in this paper. First, based on homogenization theory and solid-body analysis, unit parameters of different preset unit relative densities are determined. And a unit effective property interpolation model is constructed. Then, the macro relative density layout is optimized with density methods. In the optimization process, an efficient density filter is proposed to increase the optimization domain and satisfy minimal feature size constraint. Finally, the structure reconstruction algorithm automatically constructs the optimized cellular structure based on the unit and density information obtained in the first two processes. Numerical examples show that the proposed method efficiently obtains inhomogeneous cellular structures with better performance, compared with existing density-based methods.
KeywordsAdditive manufacturing Cellular structure Design for manufacturing Homogenization Topology optimization
The author thanks Prof. Krister Svanberg for use of the MMA optimizer. This work was supported in part by the National Natural Science Foundation of China under Grant 51677104.
- 8.Doubrovski, E. L., Verlinden, J. C., & Geraedts, J. M. P. (2011). Optimal design for additive manufacturing: Opportunities and challenges. In ASME 2011 international design engineering technical conferences and computers and information in engineering conference (pp. 635–646).Google Scholar
- 10.Francois, M. M., Sun, A., King, W. E., Henson, N. J., et al. (2017). Modeling of additive manufacturing processes for metals: Challenges and opportunities. Current Opinion in Solid State and Materials Science 21(LA-UR-16-24513).Google Scholar
- 11.Tao, W., & Ming, C. L. (2016). Design of lattice structure for additive manufacturing. In International symposium on flexible automation (pp. 325–332).Google Scholar
- 13.Dorn, W. S., Gomory, R. E., & Greenberg, H. J. (1964). Automatic design of optimal structures. Journal de Mecanique, 3, 25–52.Google Scholar
- 14.Savio, G., Meneghello, R., & Concheri, G. (2017). Optimization of lattice structures for Additive Manufacturing Technologies. In B. Eynard, V. Nigrelli, S. Oliveri, G. Peris-Fajarnes, & S. Rizzuti (Eds.), Advances on mechanics, design engineering and manufacturing (pp. 213–222). Cham: Springer.CrossRefGoogle Scholar
- 15.Chang, P. S., & Rosen, D. W. (2011). An improved size, matching, and scaling method for the design of deterministic mesoscale truss structures. Proceedings of the ASME Design Engineering Technical Conference, 2, 697–707.Google Scholar
- 18.Alzahrani, M. A. (2014). Design of truss-like cellular structures using density information from topology optimization. European Journal of Operational Research, 103(1), 198–208.Google Scholar
- 26.Gibson, L. J., & Ashby, M. F. (2014). Cellular solids: Structure and properties. Cambridge University Press, 33, 487–488.Google Scholar
- 28.Liu, J., Zheng, Y., Ma, Y., et al. (2019). A topology optimization method for hybrid subtractive–additive remanufacturing. International Journal of Precision Engineering and Manufacturing-Green Technology.Google Scholar