Concurrent topology optimization of parts and their supports for additive manufacturing with thermal deformation constraint

Liu，Yichang1; Huang，Xiaoyu1; Xiong，Yi2; Zhou，Mingdong1; Lin，Zhongqin1

2023-12-01

10.1016/j.compstruc.2023.107146

Computers and Structures   影响因子和分区

0045-7949

1879-2243

A typical manufacturing failure in powder bed additive manufacturing (AM) is caused by the collision between the already printed structure and the powder recoater due to large thermal deformation. This paper presents a density-based topology optimization (TO) approach to concurrently design parts and their supports that are not susceptible to such a manufacturing failure. The thermal deformation during the layer-by-layer AM process is predicted based on an inherent strain method, and the top surfaces' upward deformations are constrained below the powder layer thickness to avoid recoater collision. To increase the design freedom of TO, the parts and their supports are composed of lattice unit cells with different volume fractions, whose effective stiffness matrixes are predicted by the numerical homogenization and surrogate models. Besides, an overhang constraint and a two-field-based length scale control formulation are also utilized, ensuring overall manufacturability. With the proposed approach, lightweight structures with optimized mechanical properties and controllable manufacturing qualities can be obtained. Numerical examples are given to demonstrate the effectiveness of the proposed approach.

Additive manufacturing Inherent strain method Thermal deformation Topology optimization

SCI ; EI

英语

其他

National Key Research and Development Program of China[2021YFB1715400];National Natural Science Foundation of China[52075321];

Computer Science ; Engineering

Computer Science, Interdisciplinary Applications ; Engineering, Civil

WOS:001072788300001

PERGAMON-ELSEVIER SCIENCE LTD

20233714709111

Additives ; Shape optimization ; Structural design ; Topology

Structural Design, General:408.1 ; Printing Equipment:745.1.1 ; Chemical Agents and Basic Industrial Chemicals:803 ; Combinatorial Mathematics, Includes Graph Theory, Set Theory:921.4 ; Optimization Techniques:921.5

COMPUTER SCIENCE

2-s2.0-85170253742

Scopus

1.Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures,School of Mechanical Engineering,Shanghai Jiao Tong University,Shanghai,200240,China
2.School of System Design and Intelligent Manufacturing,Southern University of Science and Technology,Shenzhen,518055,China

Liu，Yichang,Huang，Xiaoyu,Xiong，Yi,et al. Concurrent topology optimization of parts and their supports for additive manufacturing with thermal deformation constraint[J]. Computers and Structures,2023,289.

Liu，Yichang,Huang，Xiaoyu,Xiong，Yi,Zhou，Mingdong,&Lin，Zhongqin.(2023).Concurrent topology optimization of parts and their supports for additive manufacturing with thermal deformation constraint.Computers and Structures,289.

Liu，Yichang,et al."Concurrent topology optimization of parts and their supports for additive manufacturing with thermal deformation constraint".Computers and Structures 289(2023).