Strut-based cellular structures have
gained remarkable
attention
in recent years due to their improved strength-to-weight ratio, energy
absorption abilities, and heat transfer properties. A key feature
of cellular structures employed in modern infrastructure and devices
is a symmetric configuration with repeating unit cells. This periodic
design makes fabrication more feasible for next-generation aerospace
and biomedical materials. However, such a design with brittle constituents
often undergoes a sudden and catastrophic failure as all unit cells
along a fracture surface tend to fail simultaneously at a critical
loading condition. In this paper, we propose an elegant solution to
achieve progressive failure by adjusting the diameter of each strut
to create asymmetric or irregular cellular structures. Finite element
simulations are conducted and validated by comparing with experiments
on additively manufactured samples. Designs are then categorized into
three failure modes and the relationship between the failure modes
and the stress–strain curves are analyzed. Lastly, simulation-based
Bayesian optimization is applied to design the structures with a more
distributed stress field before failure and therefore improve their
strength and energy absorption capabilities. Results show that the
proposed designs fail at the boundaries and the cracks grow locally
without penetrating through the entire structure, leading to more
progressive failure. This research proposes novel cellular structures
via symmetry breaking to achieve structures with promising manufacturability
and damage-tolerant failure, greatly broadening their applications.
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