Abstract
A parameterization modeling method based on finite element mesh to create complex large-scale lattice structures for AM is presented, and a corresponding approach for size optimization of lattice structures is also developed. In the modeling method, meshing technique is employed to obtain the meshes and nodes of lattice structures for a given geometry. Then, a parametric description of lattice unit cells based on the element type, element nodes and their connecting relationships is developed. Once the unit cell design is selected, the initial lattice structure can be assembled by the unit cells in each finite element. Furthermore, modification of lattice structures can be operated by moving mesh nodes and changing cross-sectional areas of bars. The graded and non-uniform lattice structures can be constructed easily based on the proposed modeling method. Moreover, a size optimization algorithm based on moving iso-surface threshold (MIST) method is proposed to optimize lattice structures for enhancing the mechanical performance. To demonstrate the effectiveness of the proposed method, numerical examples and experimental testing are presented, and experimental testing shows 11% improved stiffness of the optimized non-uniform lattice structure than uniform one.
Highlights
Lattice structure is a kind of high-efficiency cellular material, which attracts the attention of researchers and engineers for their significant potential of lightweight applications and multifunctional design opportunities, such as superior mechanical properties [1], heat transfer and thermal protection properties [2]
A size optimization algorithm based on moving iso-surface threshold (MIST) method is proposed to optimize lattice structures for enhancing the mechanical performance
Additive manufacturing (AM) is an emerging technique that provides a great flexibility for the fabrication of complex structures, and gives engineers great freedom to fabricate novel lattice structures with complex geometries [6,7,8]
Summary
Lattice structure is a kind of high-efficiency cellular material, which attracts the attention of researchers and engineers for their significant potential of lightweight applications and multifunctional design opportunities, such as superior mechanical properties (including energy absorption, strength, and stiffness) [1], heat transfer and thermal protection properties [2]. Due to the complex geometries, it is difficult for the conventional technique of manufacturing such as extrusion and molding to fabricate lattice structures directly [3,4,5], which restricts their application and development. A non-uniform lattice structure with variable unit cells and complex microstructure can achieve significantly better performance relative to the uniform one through optimizing the gradient variation of unit cells and the areas and/or orientations of the bars. AM technologies make the manufacture of the non-uniform lattice structures possible [9,10]. A highly efficient design method is required to optimize the large-scale lattice structure for enhancing mechanical performances
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