Application of layout optimization to the design of additively manufactured metallic components

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• 作者：Christopher J. Smith ; Matthew Gilbert…
• 关键词：Layout optimization ; Topology optimization ; Additive manufacture ; EBM ; 3D Printing
• 刊名：Structural and Multidisciplinary Optimization
• 出版年：2016
• 出版时间：November 2016
• 年：2016
• 卷：54
• 期：5
• 页码：1297-1313
• 全文大小：2,299 KB
• 刊物类别：Engineering
• 刊物主题：Theoretical and Applied Mechanics
  Computer-Aided Engineering and Design
  Numerical and Computational Methods in Engineering
  Engineering Design
  
• 出版者：Springer Berlin / Heidelberg
• ISSN：1615-1488
• 卷排序：54

文摘

Additive manufacturing (‘3D printing’) techniques provide engineers with unprecedented design freedoms, opening up the possibility for stronger and lighter component designs. In this paper ‘layout optimization’ is used to provide a reference volume and to identify potential design topologies for a given component, providing a useful alternative to continuum based topology optimization approaches (which normally require labour intensive post-processing in order to realise a practical component). Here simple rules are used to automatically transform a line structure layout into a 3D continuum. Two examples are considered: (i) a simple beam component subject to three-point bending; (ii) a more complex air-brake hinge component, designed for the Bloodhound supersonic car. These components were successfully additively manufactured using titanium Ti-6Al-4V, using the Electron Beam Melting (EBM) process. Also, to verify the efficacy of the process and the mechanical performance of the fabricated specimens, a total of 12 beam samples were load tested to failure, demonstrating that the target design load could successfully be met.