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Application of homogenization-based topology optimization method for a pillow bracket made with Ti-6Al-4V.
The goal of this project was to develop robust software for design and optimization of AM structural designs based on cellular structures. The outcome of this project not only enabled efficient design and optimization of cellular structured AM products but also integrated cost modeling and design requirements for several AM processes.
Additive manufacturing (AM) enables the manufacture of parts previously impossible to machine. Complex geometries can be produced as easily as simple shapes. To fully exploit the AM advantage, design tools need to be established to enable component geometry to be optimized for strength and weight by incorporating features such as lattice and porous structures. Current modeling and simulation (M&S) tools lack efficiency in designing these complex geometries for AM. Incorporating M&S in the development of the CAD or STL file will enable an efficient design and optimization of cellular structured AM products.Additive manufacturing (AM) enables the manufacture of parts previously impossible to machine. Complex geometries can be produced as easily as simple shapes. To fully exploit the AM advantage, design tools need to be established to enable component geometry to be optimized for strength and weight by incorporating features such as lattice and porous structures. Current modeling and simulation (M&S) tools lack efficiency in designing these complex geometries for AM. Incorporating M&S in the development of the CAD or STL file will enable an efficient design and optimization of cellular structured AM products.
The goal of this project was to develop robust software for design and optimization of AM structural designs based on cellular structures. The outcome of this project not only enabled efficient design and optimization of cellular structured AM products but also integrated cost modeling and design requirements for several AM processes.
This project included the following specific objectives:
The key innovation in this technology involved the utilization of micromechanics models to capture the effective behavior of cellular structures in FEA. This enabled solving topology optimization problems via FEA more efficiently.
The homogenization-based topology optimization method to optimize variable-density cellular structures efficiently included the following three steps:
The project team developed a topology optimization software to design realistic AM cellular structured components. The software has the ability to take a primitive component design and produce the optimal design in a CAD or a STL file that is ready to be additive manufactured with a number of different process-material combinations.
A beta version of the software was successfully deployed to United Technologies Research Center, ExOne, and Materials Sciences Corporation.
At the close of the project, ANSYS was in the process of implementing the developed technology into their world-leading CAE/CAD software, which is expected to be available in the next release of their software.
Enabling design optimization of AM cellular structures achieved a number of sustainability goals, including direct reduction in material use and process energy in manufacturing cellular structures by 50% as compared to bulk solids, and enhanced mechanical properties (e.g. stiffness increases by >100%; strength increases by >200%.)
The project team developed a topology optimization software to design realistic AM cellular structured components. The software has the ability to take a primitive component design and produce the optimal design in a CAD or a STL file that is ready to be additive manufactured with a number of different process-material combinations. A beta version of the software was successfully deployed to United Technologies Research Center, ExOne, and Materials Sciences Corporation. At the close of the project, ANSYS was in the process of implementing the developed technology into their world-leading CAE/CAD software, which is expected to be available in the next release of their software. Enabling design optimization of AM cellular structures achieved a number of sustainability goals, including direct reduction in material use and process energy in manufacturing cellular structures by 50% as compared to bulk solids, and enhanced mechanical properties (e.g. stiffness increases by >100%; strength increases by >200% .)