A hybrid finite element analysis and evolutionary computation method for the design of lightweight lattice components with optimized strut diameter

Abstract

Components incorporating lattice structures have become very popular lately due to their lightweight nature and the flexibility that additive manufacturing offers with respect to their fabrication. However, design optimization of lattice components has been addressed so far either with empirical approaches or with the use of topology optimization methodologies. An optimization approach utilizing multipurpose optimization algorithms has not been yet proposed. This paper presents a novel user-friendly method for the design optimization of lattice components towards weight minimization, which combines finite element analysis and evolutionary computation. The proposed method utilizes the cell homogenization technique in order to reduce the computational cost of the finite element analysis and a genetic algorithm in order to search for the most lightweight lattice configuration. A bracket consisting of both solid and lattice regions is used as a case study in order to demonstrate the validity and effectiveness of the method, with the results showing that its weight is reduced by 13.5% when using lattice structures. A discussion about the efficiency and the implications of the proposed approach is presented.

A review of the design methods of complex topology structures for 3D printing

“…In most cases, the lattice design is a multipurpose optimization issue, which is very complicated and time-consuming. A user-friendly optimization approach is introduced to solve this problem [53]. In order to reduce the calculation costs, the homogenization properties are analyzed by the finite element method, and the configuration of lattice is optimized by the genetic algorithm, as illustrated in Fig.…”

“…c Functionally graded structures[52] Fig 24. Workflow of the design and analysis of lattice structures[53]…”

Metal additive manufacturing in the commercial aviation industry: A review

“…Just to mention the fact that no specific tooling, fasteners, jigs, and fixtures would be required anymore for the assembly operations gives a good idea of the simplification extent, apart of the secondary benefit of providing enhanced agility to the system. in case a product re-design is needed, not all the system has to be re-thought but a simple CAD modification would be sufficient [175][176][177][178].…”

From Architectured Materials to Large-Scale Additive Manufacturing

“…Homogenised behaviour of architectured materials can thus be used in large structural computations, hence enabling the dissemination of architectured materials in the industry. Furthermore, computational homogenisation is the basis for computational topology optimisation (Allaire 2002;Bendsøe and Sigmund 2004;Guest and Prévost 2006;Challis et al 2008;Vicente et al 2016;Salonitis et al 2017;Asadpoure et al 2017;Khakalo and Niiranen 2017;Wang et al 2017) which will give rise to the next generation of architectured materials as it can already be seen in the works of (Laszczyk et al 2009;Andreassen et al 2014;Körner and Liebold-Ribeiro 2015;Hopkins et al 2016;Kotani and Ikeda 2016;Ghaedizadeh et al 2016;Ren et al 2016;Liu et al 2016;Dalaq et al 2016).…”