Discrete Optimization of Internal Part Structure via SLM Unit Structure-Performance Database

Li Tang,Keshan Liang,Xiqing Zhao,Qingbiao Zhang,Zhixiong Zhang

doi:10.3390/met8010045

Abstract

The structural optimization of the internal structure of parts based on three-dimensional (3D) printing has been recognized as being important in the field of mechanical design. The purpose of this paper is to present a creation of a unit structure-performance database based on the selective laser melting (SLM), which contains various structural units with different functions and records their structure and performance characteristics so that we can optimize the internal structure of parts directly, according to the database. The method of creating the unit structure-performance database was introduced in this paper and several structural units of the unit structure-performance database were introduced. The bow structure unit was used to show how to create the structure-performance database of the unit as an example. Some samples of the bow structure unit were designed and manufactured by SLM. These samples were tested in the WDW-100 compression testing machine to obtain their performance characteristics. After this, the paper collected all data regarding unit structure parameters, weight, performance characteristics, and other data; and, established a complete set of data from the bow structure unit for the unit structure-performance database. Furthermore, an aircraft part was reconstructed conveniently to be more lightweight according to the unit structure-performance database. Its weight was reduced by 36.8% when compared with the original structure, while the strength far exceeded the requirements.

Highlights

With the development of science and technology, there is an increasing demand for lightweight and functional parts in the aerospace, automotive, medical industries and other fields
Selective laser melting (SLM) is one of the new additive manufacturing (AM) techniques that emerged in the late 1980s and 1990s [1], which can directly make complex three-dimensional metal parts, according to Computer Aided Design (CAD) data, by selectively melting successive layers of metal powders [2]
This paper investigated a creation of a unit structure-performance database, which contains a wide variety of units that can be fabricated with SLM

Summary

Introduction

With the development of science and technology, there is an increasing demand for lightweight and functional parts in the aerospace, automotive, medical industries and other fields. The functional parts often have a complex structure made of various parts, which is difficult to manufacture using traditional processing technology. There are often redundant materials in conventional parts due to the inherent restrictions of the conventional manufacturing processes, which make it difficult to create lightweight versions of parts. Selective laser melting (SLM) is one of the new additive manufacturing (AM) techniques that emerged in the late 1980s and 1990s [1], which can directly make complex three-dimensional metal parts, according to Computer Aided Design (CAD) data, by selectively melting successive layers of metal powders [2]. SLM completely melts the powder material, which enables a density of approximately 100% and can maintain mechanical properties that match or even beat those of Metals 2018, 8, 45; doi:10.3390/met8010045 www.mdpi.com/journal/metals

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