Topology optimization of multi-material structures considering anisotropic yield strengths

Abstract

Multi-material structures offer the superior performance and broader designable freedom, and have gained increasing interest benefitting from the advances in additive manufacturing (AM) technique. However, the effect of anisotropic yield strength of these AM-fabricated parts on topology optimization of multi-material structures has so far received little attention. In the current work, an anisotropic strength-based topology optimization method for multi-material structures is developed for maximizing strength performance under total mass constraint, which allows for the consideration of directional dependence and tension-compression asymmetry of yield strengths based on the Tsai-Wu yield criterion. Another challenge for multi-material structures design is that the possible permutations of numerous candidate materials are unlimited, it is impossible that all combinations of multiple candidate materials are tested for the optimal strength performance of multi-material structures. To solve this problem, we propose a preselection method for the inclusion or exclusion of candidate materials based on their elastic properties, yield strengths and densities before optimization. Afterwards, our topology optimization method can automatically find the optimal combination of volume fractions of different candidate materials. Several 2D and 3D numerical examples are investigated for minimizing the maximum of failure indexes of strength for fixed total mass. The advantages of multi-material structures are verified by comparing to single-material designs. The effectiveness of the preselection method of candidate materials is also verified.