scholarly journals An Application Process of Additive Manufacturing Based on Digital Simulation and BESO Topology Optimization

2021 ◽  
Vol 2095 (1) ◽  
pp. 012097
Author(s):  
Wangjia Liu ◽  
Bingshan Liu ◽  
Gong Wang
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Digital Simulation ◽  
Stress Constraints ◽  
Spare Parts ◽  
Topological Optimization ◽  
Application Process ◽  
Three Dimensional Model ◽  
Initial Strength ◽  
Wide Range

Abstract Additive manufacturing has now entered a wide range of areas and plays an important role. There are many factors affecting the application of additive manufacturing, such as the amount of printing supplies, print product strength, print speed and so on. These factors potentially hinder the application of additive manufacturing in some typical areas, such as spare parts producing for on-orbit maintenance in space environments. Based on the improvement of the above factors, an additive manufacturing application process based on topology optimization of variable density method and digital simulation was proposed. Print volume of product was used as an explicit constraint, and the design goal of the product, such as strength and modal, was transformed into implicit stress constraints in the topology optimization of three-dimensional model, then stress constraints were independently extracted for secondary verification, finally the checked model is put into print. This process saves computational resources during optimization calculations and printing time, reduces print product’s weight, conserves supplies, and meets initial strength or modal design goals. This process greatly exploited the advantages of additive manufacturing in product manufacturing and made up for the shortcomings of traditional manufacturing processes that can not directly output a relatively abstract model after topological optimization. Under the constraints of saving material and increasing strength, it becomes optimum solution in the manufacture of specific products.

Innovative Design, Structural Optimization and Additive Manufacturing of New-Generation Turbine Blades

2021 ◽  
pp. 1-31
Author(s):  
Lorenzo Pinelli ◽  
Andrea Amedei ◽  
Enrico Meli ◽  
Federico Vanti ◽  
Benedetta Romani ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Topological Optimization ◽  
Mode Shapes ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
New Generation

Abstract The need for high performances is pushing the complexity of mechanical design at very high levels, especially for turbomachinery components. Structural topology optimization methods together with additive manufacturing techniques for high resistant alloys are considered very promising tools, but their potentialities have not been deeply investigated yet for critical rotating components like new-generation turbine blades. This research work proposes a methodology for the design, the optimization and the additive manufacturing of extremely stressed turbomachinery components like turbine blade-rows. The presented procedure pays particular attention to important aspects of the problems as fluid-structure interactions and fatigue of materials, going beyond the standard structural optimization approaches found in the literature. The numerical procedure shows robustness and efficiency, making the proposed methodology a good tool for rapid design and prototyping, and for reducing the design costs and the time-to-market typical of these mechanical elements. The procedure has been applied to a low-pressure turbine rotor to improve the aeromechanical behavior while keeping the aerodynamic performance. From the original geometry, mode-shapes, forcing functions and aerodynamic damping have been numerically evaluated and are used as input data for the following topological optimization. Finally, the optimized geometry has been verified in order to confirm the improved aeromechanical design. After the structural topology optimization, the final geometries provided by the procedure have been then properly rendered to make them suitable for additive manufacturing. Some prototypes of the new optimized turbine blade have been manufactured to be tested in terms of fatigue.

Laminated-Object-Manufacturing*/Laminated object manufacturing - A method for the production of topological optimization parts

2016 ◽  
Vol 106 (05) ◽  
pp. 354-359
Author(s):  
M. Mottahedi ◽  
P. Zahn ◽  
A. Lechler ◽  
A, Prof. Verl
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Manufacturing Method ◽  
Laminated Object Manufacturing ◽  
Maximum Stiffness ◽  
Global Topology ◽  
The Cost

Topologisch optimierte Bauteile gestatten maximale Steifigkeit bei minimalem Materialeinsatz. Für die Erzeugung solcher Topologien werden meist Algorithmen eingesetzt, die Fertigungseinschränkungen auf Kosten von optimalen Ergebnissen berücksichtigen und keine variablen Materialdichten zulassen. Dieser Fachartikel stellt ein additives Herstellungsverfahren zur Fertigung global optimaler Topologien vor. Als Ergebnis können mittels der ausgewählten Algorithmen Bauteile mit höherer Steifigkeit hergestellt werden.   The optimal topology of components leads to maximum stiffness with minimum material use. To generate these topologies, normally algorithms are employed that tackle manufacturing limitations at the cost of the optimum. This article introduces an additive manufacturing method to enable the production of global topology optimization results. The findings show that by implementing the selected algorithm the stiffness of the components are higher than what could have been produced by conventional techniques.

scholarly journals Integrated component-support topology optimization for additive manufacturing with post-machining

2019 ◽  
Vol 25 (2) ◽  
pp. 255-265 ◽  
Author(s):  
Matthijs Langelaar
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
High Performance ◽  
Process Model ◽  
Process Models ◽  
Content Type ◽  
Wide Range ◽  
Support Layout ◽  
Overhang Angle ◽  
Subtractive Machining

PurposeThe purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements.Design/methodology/approachAn integrated topology optimization is proposed using two density fields: one describing the design and another defining the support layout. Using a simplified AM process model, critical overhang angle restrictions are imposed on the design. Through additional load cases and constraints, sufficient stiffness against subtractive machining loads is enforced. In addition, a way to handle non-design regions in an AM setting is introduced.FindingsThe proposed approach is found to be effective in producing printable optimized geometries with adequate stiffness against machining loads. It is shown that post-machining requirements can affect optimal support structure layout.Research limitations/implicationsThis study uses a simplified AM process model based on geometrical characteristics. A challenge remains to integrate more detailed physical AM process models to have direct control of stress, distortion and overheating.Practical implicationsThe presented method can accelerate and enhance the design of high performance parts for AM. The consideration of post-print aspects is expected to reduce the need for design adjustments after optimization.Originality/valueThe developed method is the first to combine AM printability and machining loads in a single topology optimization process. The formulation is general and can be applied to a wide range of performance and manufacturability requirements.

scholarly journals Printing spare parts through additive manufacturing: legal and digital business challenges

2018 ◽  
Vol 29 (6) ◽  
pp. 958-982 ◽  
Author(s):  
Rosa Maria Ballardini ◽  
Iñigo Flores Ituarte ◽  
Eujin Pei
Keyword(s):  
Additive Manufacturing ◽  
Intellectual Property ◽  
Manufacturing Industry ◽  
Patent Protection ◽  
Case Study Research ◽  
Business Environment ◽  
Spare Parts ◽  
Structured Interviews ◽  
Content Type ◽  
Wide Range

Purpose The purpose of this paper is to investigate the technology, business and intellectual property issues surrounding the production of spare parts through additive manufacturing (AM) from a digital source. It aims to identify challenges to the growth of the AM spares market and propose suitable solutions. Design/methodology/approach The paper begins with a systematic literature review and theoretical analysis. This is followed by case study research through semi-structured interviews, forming the basis of a triangulated, cross-case analysis of empirical data. Findings The paper identifies several obstacles to the development of the AM-produced digital spares market. The manufacturing industry will soon be forced to re-think AM as a real manufacturing alternative. Short-term, AM technology has implications for the production of components for legacy systems for which tooling facilities no longer exist. Long-term, AM will be used to produce a wide range of components especially when product and/or service functionality can be increased. To enable companies to navigate current uncertainties in the patent framework (especially the “repair vs make” doctrine), new intellectual property rights strategies could be developed around patenting both complex devices and their individual components, and seeking patent protection for CAD files. Further harmonization of the EU legal framework, the interpretation of claims and the scope of protection offered in the context of spare parts, will also be important. Originality/value This study pinpoints key issues that need to be addressed within the European AM business environment and the patent system and proposes recommendations for business and legal frameworks to promote the growth of a stable European digital spare parts market.

Topology Optimization of the Transmission Shift Fork

2013 ◽  
Vol 325-326 ◽  
pp. 167-171
Author(s):  
Zuo Shi Liu ◽  
Xiao Hong Zhang ◽  
Xiu Qin Gao
Keyword(s):  
Topology Optimization ◽  
High Reliability ◽  
Optimization Technique ◽  
Three Dimensional ◽  
Optimization Theory ◽  
Product Structure ◽  
Structure Design ◽  
Topological Optimization ◽  
Dimensional Model ◽  
Three Dimensional Model

This paper introduces the topology optimization theory and mathematical model of the variable density method, to use HyerMesh Optistruct module, designs the structure of the transmission shift fork by topological optimization. First establishes the original three-dimensional model of the fork according to the design requirement, then in the HyerMesh establishes the finite element model of the fork, and sets the fork load constraints and the manufacturing process constraints, finally gets a reasonable distribution of materials, uniform force and can be used for manufacturing the ideal topology configuration, and then by the Ossmooth tool obtains directly optimized three-dimensional model. The topological optimization technique, can effectively guides the design personnel of product structure modification and new product structure design, makes product design structure high reliability, economical.

scholarly journals Assessment of the Potential Economic Impact of the Use of AM Technologies in the Cost Levels of Manufacturing and Stocking of Spare Part Products

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1429 ◽  
Author(s):  
Joaquim Minguella-Canela ◽  
Sergio Morales Planas ◽  
Joan Gomà Ayats ◽  
M. de los Santos López
Keyword(s):  
Additive Manufacturing ◽  
Economic Impact ◽  
General Equation ◽  
Spare Part ◽  
Spare Parts ◽  
Added Value ◽  
Topological Optimization ◽  
Manufacturing Technologies ◽  
The Cost

Additive manufacturing (AM) technologies are appropriate manufacturing technologies to produce low rotation products of high added value. Products in the spare parts business usually have discontinuous demand levels of reduced numbers of parts. Indeed, spare parts inventories handle myriad of products that require big immobilized investments while having an intrinsic risk of no-use (for example due to obsolescence or spoilage). Based on these issues, the present work analyses the fundamental cost factors in a real case study of a company dedicated to the supply of spare parts for fluid conduction systems. Real inventory data is assessed to determine the product taxonomy and its associated costs. A representative product of the stock is analyzed in detail on original manufacturing costs, in AM costs and then redesigned with topological optimization to reduce the AM cost levels (via design for additive manufacturing). A general equation for cost assessment is formulated. Given the specific data collected from the company, the parameters in this general equation are calculated. Finally, the general equation and the product cost reduction achieved are used to explore the potential economic impact of the use of AM technologies in the cost levels of manufacturing and stocking of spare part products.

scholarly journals A review on the topology optimization of the fiber-reinforced composite structures

2021 ◽  
pp. 54-72
Author(s):  
Zheng Hu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Fiber Orientation ◽  
Composite Structures ◽  
Optimization Design ◽  
Optimization Methods ◽  
Topology Design ◽  
Topological Optimization ◽  
Main Challenge ◽  
Orientation Optimization

According to the requirements of the aerospace industry for high strength, high stiffness, and lightweight structural parts, topology optimization has been proved to be an effective product design method. As one of the most conceptual and prospective structural optimization design methods, topology optimization intends to seek the optimal layout of materials in an allowed design region under a given load and boundary conditions. Thus, the object of study in the article is the method of topological optimization of aircraft structures. The goal of this article is to analyze the existing approaches, algorithms, as well as application of the method of topological optimization in the aerospace field in applied problems. The tasks are to describe the existing various approaches methods, features, and research directions of topological optimization as well as to study the possibility of application in the manufacturing process of composite structures. The following results were obtained. The optimization methods are briefly explained and compared, and the advantages and limitations of each approach are discussed. The various ways of simultaneous optimization of fiber orientation and structural topology were described and analyzed. The features of different methods of continuous fiber orientation optimization method were reviewed. The discrete fiber orientation optimization methods were represented. The possibility of multi-scale concurrent topological optimization was described. The combination of topology optimization and additive manufacturing was considered. Finally, the topology optimization of FRC structures which have been resolved in literature are reviewed and the potential research fields requiring more investigation are pointed out. Conclusions. In the article, a comprehensive review of the topology optimization design of FRC structures was presented. The promising way is to combine topology optimization with additive manufacturing techniques. However, these proposed methods may not suitable for other more complex problems, such as bucking stability and natural frequency. Hence, the topology optimization design of complex FRC components under complicated conditions is the main challenge in the future. This can be a new trend in the topology design of FRC structures.

scholarly journals Topology Optimization of Automotive Gear using Fea

2019 ◽  
Vol 8 (4) ◽  
pp. 1079-1084
Keyword(s):  
Topology Optimization ◽  
Stress Distribution ◽  
Weight Reduction ◽  
Power Transmission ◽  
Topological Optimization ◽  
Tangential Load ◽  
Wide Range ◽  
Bending Stresses ◽  
Major Application ◽  
Two Wheeler

Gears are the key elements used to transmit power or motion from on shaft to another and it has wide range of applications. It's one of the major application is in the automobile gear box. Generally, gears fail when the working stress exceeds than the maximum permissible value. Here the generated stresses are directly in relation to amount power produced inside an engine, as well as also on torque. This study mainly focuses to identify the magnitude of the bending stresses generated in the selected gear set of CVT of a two-wheeler during power transmission as well as also tried to find different ways for reducing weight of the gear. Hence integrating the feature of topology optimization as a part of weight reduction over an existing part is considered as the key parameter of assessment for this work. In this study, gears of CVT gearbox of two-wheeler is analyzed for static loading under the application of tangential load resulting from maximum torque in the given application. After the study of the stress distribution on existing gears, the material removal area for weight reduction is identified on selected gears then the same study for stress distribution is carried out for proposed designs of topological optimization. Hence the both existing and proposed optimized designs are analyzed under static structural analysis for same loading and results for stress distribution are compared.

scholarly journals Additive manufacturing and topology optimization of magnetic materials for electrical machines

2021 ◽  
Vol 23 (3) ◽  
pp. 14-33
Author(s):  
A. R. Safin ◽  
Ranjan Kumar Behera
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Magnetic Materials ◽  
Permanent Magnets ◽  
Electrical Machines ◽  
Production Costs ◽  
Comprehensive Overview ◽  
Additive Production ◽  
Global Trends ◽  
Wide Range

THE PURPOSE. To consider the technologies for the manufacture of permanent magnets and their areas of application. To identify global trends in the change in demand for rare earth metals. To study the prospects for the development of additive production of polymer magnetic materials. METHODS. When studying this issue, an analysis of a wide range of domestic and foreign sources of scientific literature was used. RESULTS. Prospective technologies for the additive production of polymer magnetic materials for a variety of applications have been studied. The need to establish a relationship between the properties of the starting material, the diameters of the extrusion nozzles, the printing parameters, as well as the mechanical and functional properties of the resulting magnets is indicated. CONCLUSION. This article provides a comprehensive overview of recent advances in the application of additive manufacturing, topology optimization and their integration for electrical machines and their magnetic components. Additive manufacturing technologies such as 3D printing, BAAM - the technology has potential advantages such as lower production costs, elimination of the need to make molds, the ability to create permanent magnets with field profiles and magnetic properties that cannot be obtained using modern methods. The considered technologies can be used as a tool in the design and development of innovative magnets for electric motors, which will make the most of the magnetic flux and thereby increase the energy efficiency of drive systems. This will allow rapid prototyping of parts and reduce the time to market for new products.

scholarly journals Topology optimization of the tool holder produced with additive manufacturing

2021 ◽  
Vol 1199 (1) ◽  
pp. 012086
Author(s):  
M Stepanek ◽  
K Raz ◽  
Z Chval
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Production Technology ◽  
Weight Reduction ◽  
Laser Sintering ◽  
Topological Optimization ◽  
Manufacturing Constraints ◽  
Direct Metal Laser Sintering ◽  
Tool Holder

Abstract This paper deals with the topology optimizations of tool holder where three different mass targets were required. The holder was loaded with 499 N. Weight reduction of the tool holder placed in tool turret can positively affect the bearing durability. Easier manipulation with the holder is one of the results. In the process of the topological optimization manufacturing constraints, such as overhang prevention, self-supporting and material spreading were defined for needs of Direct Metal Laser Sintering production technology. Structural analyses of three obtained geometries were simulated for evaluation of the stiffness in three main directions of the tool holder. Finally, the weight and the stiffness of each individual geometry was compared and prepared for manufacturing.

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