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Towards Integrating Topology Optimization And Additive Manufacturing
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Book Synopsis Towards Integrating Topology Optimization and Additive Manufacturing by : Amir M. Mirzendehdel
Download or read book Towards Integrating Topology Optimization and Additive Manufacturing written by Amir M. Mirzendehdel and published by . This book was released on 2017 with total page 120 pages. Available in PDF, EPUB and Kindle. Book excerpt: Topology optimization (TO) is an automated design tool that integrates mathematical modeling with numerical analysis to automatically reduce weight and material usage while ensuring certain prescribed constraints on performance of the design are satisfied. The high-performance light-weight designs created through topology optimization are often free-form and organic, manufacturing of which through traditional casting, forming, or subtractive technologies can become quite challenging. Additive manufacturing (AM) is a class of more modern technologies that seem to alleviate this issue by fabricating complex parts layer by layer. On the other hand, the cost of additively manufactured parts increase significantly with material usage. Therefore, optimizing designs can reduce material usage, build time, and post-process time to make AM worthwhile. Thus, TO and AM complement each other to fabricate ever more complex high performance and customized yet affordable products. However, for these technologies to be integrated, there are certain issues, such as extraneous support structures or material anisotropy, that need to be considered within the optimization. Focus of this thesis is mainly on: 1. Addressing challenges on reducing amount of support structure and considering process-induced anisotropy throughout the optimization process. 2. Exploiting the capabilities of AM in free-form fabrication to improve performance by generating more complex multi-material designs. In other words, the present thesis attempts to make advances on integrating the two modern and promising fields, topology optimization and additive manufacturing by developing optimization algorithms that generate optimized designs while tracing Pareto frontiers. Perhaps the most important benefit of this class of methods is the fact that intermediate topologies remain structurally valid, thus iterative solvers can converge much faster. Further, these intermediate designs are local optimum solutions. These traits make these methods well-suited for rapidly exploring the design space to find freeform designs while ensuring their structural integrity.
Book Synopsis Towards Design Automation for Additive Manufacturing by : Anton Wiberg
Download or read book Towards Design Automation for Additive Manufacturing written by Anton Wiberg and published by Linköping University Electronic Press. This book was released on 2019-10-14 with total page 53 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Integrated Topology Optimization Design and Process Planning for Additive Manufacturing by : Dylan J. Bender
Download or read book Integrated Topology Optimization Design and Process Planning for Additive Manufacturing written by Dylan J. Bender and published by . This book was released on 2019 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Industry 4.0 demands that the systems and processes in today's product design and manufacturing not just be automated, but to be robust and containing many feedback mechanisms which enables it to be self-correcting. The hypothetical upcoming Industry 5.0 promises on demand and personalized products which this thesis aims to take a step in the direction of. It is proposed that an integrated and optimized process for structural topology optimization and subsequent additive manufacturing is possible for automated design and manufacturing starting from its problem definition. An improvement on the benchmarked topology optimization methods is shown which allows the user control over the optimization's convergence characteristics which is then further studied to find a robust set of optimization parameters. The resulting topology of the structure is then analyzed for its optimal printing orientation based on a custom-made algorithm which minimizes manufacturing costs. Furthermore, the structure is then sliced for instruction generation of layer-based manufacturing techniques in a novel fashion which also serves to provide feedback of the manufacturing process planning to the topology optimization design stage.
Book Synopsis Algorithm-Driven Truss Topology Optimization for Additive Manufacturing by : Christian Reintjes
Download or read book Algorithm-Driven Truss Topology Optimization for Additive Manufacturing written by Christian Reintjes and published by Springer Nature. This book was released on 2022-02-01 with total page 219 pages. Available in PDF, EPUB and Kindle. Book excerpt: Since Additive Manufacturing (AM) techniques allow the manufacture of complex-shaped structures the combination of lightweight construction, topology optimization, and AM is of significant interest. Besides the established continuum topology optimization methods, less attention is paid to algorithm-driven optimization based on linear optimization, which can also be used for topology optimization of truss-like structures. To overcome this shortcoming, we combined linear optimization, Computer-Aided Design (CAD), numerical shape optimization, and numerical simulation into an algorithm-driven product design process for additively manufactured truss-like structures. With our Ansys SpaceClaim add-in construcTOR, which is capable of obtaining ready-for-machine-interpretation CAD data of truss-like structures out of raw mathematical optimization data, the high performance of (heuristic-based) optimization algorithms implemented in linear programming software is now available to the CAD community.
Book Synopsis Topology Optimization Subject to Additive Manufacturing Constraints by : Moritz Ebeling-Rump
Download or read book Topology Optimization Subject to Additive Manufacturing Constraints written by Moritz Ebeling-Rump and published by . This book was released on 2019 with total page 228 pages. Available in PDF, EPUB and Kindle. Book excerpt: In Topology Optimization the goal is to find the ideal material distribution in a domain subject to external forces. The structure is optimal if it has the highest possible stiffness. A volume constraint ensures filigree structures, which are regulated via a Ginzburg-Landau term. During 3D Printing overhangs lead to instabilities, which have only been tackled unsatisfactorily. The novel idea is to incorporate an Additive Manufacturing Constraint into the phase field method. A rigorous analysis proves the existence of a solution and leads to first order necessary optimality conditions. With an Allen-Cahn interface propagation the optimization problem is solved iteratively. At a low computational cost the Additive Manufacturing Constraint brings about support structures, which can be fine tuned according to engineering demands. Stability during 3D Printing is assured, which solves a common Additive Manufacturing problem.
Book Synopsis Plastics Application Technology for Lightweight Automobiles by : Sudhakar Marur
Download or read book Plastics Application Technology for Lightweight Automobiles written by Sudhakar Marur and published by SAE International. This book was released on 2013-08-06 with total page 374 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is focused on the use of plastics in automobiles for traditional applications, as well as for more advanced uses such as under-the-hood components. Engineering thermoplastics offer the ability to tailor-make components from polymers, and to design parts for enhanced performance, new functionality, part integration, and elimination of secondary operations. Parts made from engineering thermoplastics can be manufactured within specified cost constraints, and using manufacturing methods that offer a wide range of production flexibility. A decade of research and real-world applications is presented by the authors on application technology development for various aspects of automotive design – concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making. Additional advantages of plastics are covered and include greater styling, improved energy absorption, and enhanced performance over traditional materials, all while fostering environmental sustainability and reducing overall vehicle weight for next generation automobiles.
Book Synopsis Topology Optimization for Additive Manufacturing Involving High-Cycle Fatigue by : Shyam Suresh
Download or read book Topology Optimization for Additive Manufacturing Involving High-Cycle Fatigue written by Shyam Suresh and published by Linköping University Electronic Press. This book was released on 2020-05-05 with total page 41 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Topology Design Methods for Structural Optimization by : Osvaldo M. Querin
Download or read book Topology Design Methods for Structural Optimization written by Osvaldo M. Querin and published by Butterworth-Heinemann. This book was released on 2017-06-09 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: Topology Design Methods for Structural Optimization provides engineers with a basic set of design tools for the development of 2D and 3D structures subjected to single and multi-load cases and experiencing linear elastic conditions. Written by an expert team who has collaborated over the past decade to develop the methods presented, the book discusses essential theories with clear guidelines on how to use them. Case studies and worked industry examples are included throughout to illustrate practical applications of topology design tools to achieve innovative structural solutions. The text is intended for professionals who are interested in using the tools provided, but does not require in-depth theoretical knowledge. It is ideal for researchers who want to expand the methods presented to new applications, and includes a companion website with related tools to assist in further study. Provides design tools and methods for innovative structural design, focusing on the essential theory Includes case studies and real-life examples to illustrate practical application, challenges, and solutions Features accompanying software on a companion website to allow users to get up and running fast with the methods introduced Includes input from an expert team who has collaborated over the past decade to develop the methods presented
Book Synopsis Topology Optimization in Engineering Structure Design by : Jihong Zhu
Download or read book Topology Optimization in Engineering Structure Design written by Jihong Zhu and published by Elsevier. This book was released on 2016-11-08 with total page 296 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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
Book Synopsis Using Topology Optimization to Improve Design for Additive Manufacture by : Ian Ferguson
Download or read book Using Topology Optimization to Improve Design for Additive Manufacture written by Ian Ferguson and published by . This book was released on 2015 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Multiscale Structural Topology Optimization by : Liang Xia
Download or read book Multiscale Structural Topology Optimization written by Liang Xia and published by Elsevier. This book was released on 2016-04-27 with total page 186 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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
Book Synopsis Rapid Manufacturing by : Neil Hopkinson
Download or read book Rapid Manufacturing written by Neil Hopkinson and published by John Wiley & Sons. This book was released on 2006-02-22 with total page 304 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Development of a Process for Determining Minimum Feature Size in Additive Manufacturing with Applications to Topology Optimization by : Benjamin M. Weiss
Download or read book Development of a Process for Determining Minimum Feature Size in Additive Manufacturing with Applications to Topology Optimization written by Benjamin M. Weiss and published by . This book was released on 2017 with total page 185 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) is opening a new creative landscape for designers. Freedom of form and material creates opportunities for customization, increased functionality, and higher complexity in manufactured objects. Characterizing and understanding the unique manufacturing constraints of AM is a key to enabling the designer to leverage the full potential of AM to produce highly complex geometries. In this work, “minimum feature size”, defined as the smallest scale at which a feature of a particular shape in a particular orientation can be manufactured, is examined in detail. A parameterization for shape and orientation of small features is developed, and an adaptive, iterative experimental procedure is created to accurately estimate the minimum feature size for a particular feature type in the parameter space. A design of experiments process is used to systematically explore the minimum feature size over the space of parameterized shapes and orientations. This process is applied to three different AM platforms, and in each case minimum feature size spans an order of magnitude over the set of considered features. The data collected are used to create a parametric design rule for each process, a function which provides a detailed map of the minimum feature size achievable over the parameter space. The parametric design rule is applied to typical design problems, used to assess existing 3D models for manufacture, and applied to design optimization frameworks. The parametric design rules produced are found to more tightly follow the actual capabilities of the AM processes, increasing the envelope for complexity compared with existing design guidelines consisting of one or two constant minimum feature sizes and improving accuracy in predicting the minimum feature sizes for new geometries by as much as 50%. Application is made to three design problems, realizing significant improvements in each case. The experimental study of minimum feature size is complemented by an adaptation of topology optimization to incorporate the parametric design rules into an automated design process. A new variant of the Moving Morphable Components (MMC) approach is created, improving convergence through a “bootstrapping” approach and integrating the feature-dependent design rules to ensure manufacturability of the result. Experimentally-verified manufacturable outputs are achieved while sacrificing less than 5% of the objective function value for several test problems. By bringing together experimental assessment of minimum feature size and design optimization through the creation of parametric design rules, a novel, reproducible, and practical process for ensuring manufacturability of optimized designs is created.
Book Synopsis Progress Toward Topology Optimization (TO) for Additive Manufacturing (AM) and Fatigue by : Terrence E. Johnson
Download or read book Progress Toward Topology Optimization (TO) for Additive Manufacturing (AM) and Fatigue written by Terrence E. Johnson and published by . This book was released on 2017 with total page 20 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Author :National Academies of Sciences, Engineering, and Medicine Publisher :National Academies Press ISBN 13 :0309449758 Total Pages :149 pages Book Rating :4.3/5 (94 download)
Book Synopsis Predictive Theoretical and Computational Approaches for Additive Manufacturing by : National Academies of Sciences, Engineering, and Medicine
Download or read book Predictive Theoretical and Computational Approaches for Additive Manufacturing written by National Academies of Sciences, Engineering, and Medicine and published by National Academies Press. This book was released on 2016-12-21 with total page 149 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) methods have great potential for promoting transformative research in many fields across the vast spectrum of engineering and materials science. AM is one of the leading forms of advanced manufacturing which enables direct computer-aided design (CAD) to part production without part-specific tooling. In October 2015 the National Academies of Sciences, Engineering, and Medicine convened a workshop of experts from diverse communities to examine predictive theoretical and computational approaches for various AM technologies. While experimental workshops in AM have been held in the past, this workshop uniquely focused on theoretical and computational approaches and involved areas such as simulation-based engineering and science, integrated computational materials engineering, mechanics, materials science, manufacturing processes, and other specialized areas. This publication summarizes the presentations and discussions from the workshop.
Book Synopsis Additive Manufacturing: Design, Processes and Applications by : Panagiotis Stavropoulos
Download or read book Additive Manufacturing: Design, Processes and Applications written by Panagiotis Stavropoulos and published by Springer Nature. This book was released on 2023-07-01 with total page 139 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is a comprehensive guide to Additive Manufacturing (AM) product development. It offers a practical, reader-friendly approach to integrating the stages of product development. It covers current design and manufacturing strategies with a step-by-step approach, divided into three pillars: design, processes, and applications. The book addresses the challenges hindering the industrial application of AM and provides a roadmap for its successful implementation. It discusses specific AM case studies and hybrid AM cell and production line setups, with the goal of achieving high-quality, low-cost products that are both flexible and productive. The book concludes with an examination of Industry 4.0 capabilities in decentralized manufacturing. It is aimed to be read by researchers and professionals in industry who are interested in the development and potential of additive manufacturing, and will help to lead to wider adoption of AM.
Book Synopsis Additive Manufacturing Handbook by : Adedeji B. Badiru
Download or read book Additive Manufacturing Handbook written by Adedeji B. Badiru and published by CRC Press. This book was released on 2017-05-19 with total page 928 pages. Available in PDF, EPUB and Kindle. Book excerpt: Theoretical and practical interests in additive manufacturing (3D printing) are growing rapidly. Engineers and engineering companies now use 3D printing to make prototypes of products before going for full production. In an educational setting faculty, researchers, and students leverage 3D printing to enhance project-related products. Additive Manufacturing Handbook focuses on product design for the defense industry, which affects virtually every other industry. Thus, the handbook provides a wide range of benefits to all segments of business, industry, and government. Manufacturing has undergone a major advancement and technology shift in recent years.
