Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation

Cheng, Lin; Zhang, Pu; Biyikli, Emre; Bai, Jiaxi; Robbins, Joshua; To, Albert C.

doi:10.1108/rpj-04-2016-0069

Cited by 195 publications

(81 citation statements)

References 52 publications

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“…Accordingly, engineers can design more mechanisms that cannot be processed by traditional manufacturing technology that not only meet the requirements of the work, but also provide superior performance. Such mechanisms include aerospace structures based on topology optimization 7,8 and functional gradient lattice structures based on topology optimization [15][16][17] . This type of structure can greatly reduce the mass of the structure, and adjust the optimization direction according to the designer's needs so that the structure can have reduced mass and meet the needs of the specific environment.…”

Section: D-printing Process Design Of Lattice Compressor Impeller Bamentioning

confidence: 99%

3D-printing process design of lattice compressor impeller based on residual stress and deformation

Jia

Zhang

2020

Sci Rep

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The application of a lattice structure in the lightweight design of compressor impellers can reduce their mass and moment of inertia, hence improving the effective carrying of aircraft and reducing the start and braking moments of the impeller. The feasibility of a processing-lattice compressor impeller is the prerequisite for its application. To control the residual deformation and residual stress effectively, a computer-aided design technique is used to simulate the manufacturing process of a compressor impeller. The residual deformation and stress of the compressor impeller during the additive manufacturing process is calculated. The material-stacking process and base-plate- and support-removal process of a TiAl6V4 impeller printed by an SLM280 metal 3D printer are simulated by the finite-element method. The results show that some change in the laser printing parameters leads to a significant impact on the residual stress and deformation amplitude of the impeller. The residual deformation and residual stress of the lattice compressor impeller with the same geometrical appearance after processing are less than the corresponding amplitude of the solid compressor impeller, which also shows that the printed lattice compressor impeller can more easily achieve the design requirements.

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Section: D-printing Process Design Of Lattice Compressor Impeller Bamentioning

confidence: 99%

3D-printing process design of lattice compressor impeller based on residual stress and deformation

Jia

Zhang

2020

Sci Rep

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“…These ideas have been extended to multi-material cellular optimization as well [27]. Recent work has looked at implementing some of these ideas, inverse homogenization in particular, towards integration into commercial FEA code [28,29]. Finally, cellular automata methods have also been proposed to design materials [30] and microstructures [31], and machine learning methods are also beginning to be applied to materials design [32,33].…”

Section: Simulation-driven Cellular Materials Designmentioning

confidence: 99%

Classification and Selection of Cellular Materials in Mechanical Design: Engineering and Biomimetic Approaches

Bhate

Penick

Ferry

et al. 2019

Designs

129

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Recent developments in design and manufacturing have greatly expanded the design space for functional part production by enabling control of structural details at small scales to inform behavior at the whole-structure level. This can be achieved with cellular materials, such as honeycombs, foams and lattices. Designing structures with cellular materials involves answering an important question: What is the optimum unit cell for the application of interest? There is currently no classification framework that describes the spectrum of cellular materials, and no methodology to guide the designer in selecting among the infinite list of possibilities. In this paper, we first review traditional engineering methods currently in use for selecting cellular materials in design. We then develop a classification scheme for the different types of cellular materials, dividing them into three levels of design decisions: tessellation, element type and connectivity. We demonstrate how a biomimetic approach helps a designer make decisions at all three levels. The scope of this paper is limited to the structural domain, but the methodology developed here can be extended to the design of components in thermal, fluid, optical and other areas. A deeper purpose of this paper is to demonstrate how traditional methods in design can be combined with a biomimetic approach.

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“…Daynes et al [30] presented a combined methodology of topology optimization and size optimization. In addition, Cheng et al [31] took the anisotropic property of cellular materials into account by the homogenization method. In addition, Wang et al [32] used an efficient homogenization-based topology optimization method to generate a variable-density honeycombs cellular structure for natural frequency optimization.…”

Section: Related Workmentioning

confidence: 99%

Design and Optimization of Graded Cellular Structures With Triply Periodic Level Surface-Based Topological Shapes

Dai

Tang

et al. 2019

Journal of Mechanical Design

107

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Periodic cellular structures with excellent mechanical properties widely exist in nature. A generative design and optimization method for triply periodic level surface (TPLS)-based functionally graded cellular structures is developed in this work. In the proposed method, by controlling the density distribution, the designed TPLS-based cellular structures can achieve better structural or thermal performances without increasing its weight. The proposed technique can be divided into four steps. First, the modified 3D implicit functions of the triply periodic minimal surfaces are developed to design different types of cellular structures parametrically and generate spatially graded cellular structures. Second, the numerical homogenization method is employed to calculate the elastic tensor and the thermal conductivity tensor of the cellular structures with different densities. Third, the optimal relative density distribution of the object is computed by the scaling laws of the TPLS-based cellular structures added optimization algorithm. Finally, the relative density of the numerical results of structure optimization is mapped into the modified parametric 3D implicit functions, which generates an optimum lightweight cellular structure. The optimized results are validated subjected to different design specifications. The effectiveness and robustness of the obtained structures is analyzed through finite element analysis and experiments. The results show that the functional gradient cellular structure is much stiffer and has better heat conductivity than the uniform cellular structure.

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Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation

Cited by 195 publications

References 52 publications

3D-printing process design of lattice compressor impeller based on residual stress and deformation

3D-printing process design of lattice compressor impeller based on residual stress and deformation

Classification and Selection of Cellular Materials in Mechanical Design: Engineering and Biomimetic Approaches

Design and Optimization of Graded Cellular Structures With Triply Periodic Level Surface-Based Topological Shapes

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