Abstract
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.
Highlights
Additive manufacturing (AM) technologies are rapidly advancing and being adopted in a wide variety of industries
Through AM, designers are no longer restricted by traditional fabrication constraints, and a clear need arises for design tools that help to fully exploit this new design freedom (Rosen, 2014; Thompson et al, 2016)
Topology optimization shares the characteristic of an enormous design freedom with AM processes, and it is universally recognized as an ideal design approach for AM
Summary
Additive manufacturing (AM) technologies are rapidly advancing and being adopted in a wide variety of industries. Topology optimization shares the characteristic of an enormous design freedom with AM processes, and it is universally recognized as an ideal design approach for AM. Classical topology optimization formulations do not consider specific restrictions of typical AM processes. From a design-for-manufacturing viewpoint, ideally all restrictions of the manufacturing process are already included at the design stage (Gibson et al, 2015). One important restriction common to many AM processes is the maximum overhang angle of downward-facing surfaces of a component. Surfaces that violate this restriction need to be supported by sacrificial support material.
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