Constrained Topology Optimization For Additive Manufacturing Of Structural Components In Ansys®

Abstract

Topology Optimization is currently the main technique to optimize an objects structural design. This method commonly produces parts that have exceedingly complex geometry. Additive manufacturing (AM) is the main manufacturing process to produce these optimized designs due to the flexibility and speed it offers. However, results of topology optimization without considering manufacturing process limits, even AM ones, may result in designs that are expensive and difficult to build. This paper presents a topology optimization filter that minimizes the effect of overhang structures. These structures are very difficult to manufacture using conventional AM techniques. In order to constrain the gradient compliances with respect to densities and converge the results towards a structure with the least amount of overhang structures, sensitivities are modified using the proposed filter. To implement the proposed filter and the base topology optimization methods ESO and SIMP, ANSYS Parametric Design Language (APDL) is employed within the ANSYS ® Workbench™ environment. The results of a case study using the different topology optimization methods are investigated. Finally, an implementation of the proposed AM filter is used to solve an MBB-beam problem. The result is a structure that needs the least amount of support structure.

Process planning and optimization techniques in additive manufacturing

“…In papers [18] and [27] the authors paid special attention to decrease the production cost by concurrent optimizing MAM (Metal Additive Manufacturing) process variables and part structure.…”