Abstract
This paper presents a unified process of digital structural topological optimization and digital manufacturing. Based on a level set method and an augmented Lagrange multiplier method, the cloud data of the level-set surface for the optimized result are obtained. A new triangular facet approximation method to approach the level-set surface is presented to extract the zero-level-set cloud data of the topologically optimized structure. By using a slice method and the distance formula between two points, the extracted cloud data of the boundaries of the optimized structures are classified into different boundary curves. Along with the standards of the digital manufacturing, the sorted points are translated into a processing program for digital manufacturing of the optimized structures by using an automatic programming technology. The Wire-cut Electrical Discharge Machining is employed to manufacture digitally the work-piece with the optimized design. The digital structural optimization and manufacturing of a 2-D work-piece validate the method and process presented in this paper.
Highlights
Topology optimization is identified as one of the most challenging tasks in structural design, and has been applied in various industries, especially aeronautical, spaceship and civil industries
According to the authors’ investigation, a variety of numerical methods for structural optimization have been developed, very few studies on turning the level set topology optimization result into a practical work-piece by digital manufacturing have been carried out
The level set function and the Augmented Lagrangian method are employed for digital topology optimization design, and the cloud data of the level set model is extracted by using a new triangular facet approximation method to approach the level set surface of the optimized result
Summary
Topology optimization is identified as one of the most challenging tasks in structural design, and has been applied in various industries, especially aeronautical, spaceship and civil industries. According to the authors’ investigation, a variety of numerical methods for structural optimization have been developed, very few studies on turning the level set topology optimization result into a practical work-piece by digital manufacturing have been carried out. The level set function and the Augmented Lagrangian method are employed for digital topology optimization design, and the cloud data of the level set model is extracted by using a new triangular facet approximation method to approach the level set surface of the optimized result In this method, the parametric equations of the straight lines surrounding the triangular facets are employed to obtain the boundary data of the optimized structure, and the extracted cloud data based on the optimized structure boundaries are classified into different boundary curves by employing a slice method and the distance formula. The Wire-cut Electrical Discharge Machining is employed to complete the digital manufacturing
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