Optimization of parts manufactured using continuous fiber three-dimensional printing technology

Fedulov, Boris; Fedorenko, Alexey; Khaziev, Aleksey; Антонов, Ф. К.

doi:10.1016/j.compositesb.2021.109406

Cited by 48 publications

(15 citation statements)

References 27 publications

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“…While mainly concentrating on orientation optimization, some approaches do ultimately generate fiber paths. For example, Fedulov et al [2021] first optimized density and orientation and then used third-party software for printing trajectory generation; Schmidt et al [2020] performed density and orientation optimization and generated streamlines using the 4th-order Runge-Kutta integrator for visualization.…”

Section: Related Work 21 Fiber Orientation Optimization In 3d Printingmentioning

confidence: 99%

More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites

Sun¹,

Roeder²,

Xue³

et al. 2022

Preprint

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In 3D printing, stiff fibers (e.g., carbon fiber) can reinforce thermoplastic polymers with limited stiffness. However, existing commercial digital manufacturing software only provides a few simple fiber layout algorithms, which solely use the geometry of the shape. In this work, we build an automated fiber path planning algorithm that maximizes the stiffness of a 3D print given specified external loads. We formalize this as an optimization problem: an objective function is designed to measure the stiffness of the object while regularizing certain properties of fiber paths (e.g., smoothness). To initialize each fiber path, we use finite element analysis to calculate the stress field on the object and greedily "walk" in the direction of the stress field. We then apply a gradient-based optimization algorithm that uses the adjoint method to calculate the gradient of stiffness with respect to fiber layout. We compare our approach, in both simulation and real-world experiments, to three baselines: (1) concentric fiber rings generated by Eiger, a leading digital manufacturing software package developed by Markforged, ( 2) greedy extraction on the simulated stress field (i.e., our method without optimization), and (3) the greedy algorithm on a fiber orientation field calculated by smoothing the simulated stress fields. The results show that objects with fiber paths generated by our algorithm achieve greater stiffness while using less fiber than the baselines-our algorithm improves the Pareto frontier of object stiffness as a function of fiber usage. Ablation studies show that the smoothing regularizer is needed for feasible fiber paths and stability of optimization, and multi-resolution optimization help reduce the running time compared to single-resolution optimization.CCS Concepts: • Applied computing → Computer-aided manufacturing.

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Section: Related Work 21 Fiber Orientation Optimization In 3d Printingmentioning

confidence: 99%

More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites

Sun¹,

Roeder²,

Xue³

et al. 2022

Preprint

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“…他方で，構造設計の最適化においてトポロジー最適化は有用な手段である (Bendsøe and Sigmund, 2003) (Pedersen, 2000)．トポロジー最適化は構造物の位相(穴の数)の変化をも許容するような自由度が高い最適化手法であり，設計者の勘や経験に依存しない最適設計を可能とする．しかし，複合材構造を対象としたトポロジー最適化においては，従来のマクロ構造の最適化に限定されていては不十分であり，ミクロな情報である局所的な繊維配向をも最適化する必要がある．そのためトポロジー・配向の同時最適化法に関する研究は構造最適化分野では多く発表されている．また，例を挙げると Anisoprint 社の Composer シリーズのような 3 次元連続繊修正箇所維強化複合材を造形可能な 3D プリンターが既に市販されており，複合材構造の積層造形技術も発達してきている (Fedulov et al, 2021)．往々にして製造困難な構造を解として出力するトポロジー最適化は積層造形と相性が良く，このような背景も相まって繊維強化複合材のトポロジー最適化は注目を集めている．トポロジー・配向最適化においては繊維配向角が一定の区間中の任意の角度を取り得るとした Continuous Fiber Orientation Optimization(CFAO) と，配向角が取り得る角度を複数事前に指定する Discrete Material Optimization(DMO) の二つのアプローチに大別される (Luo and Guest, 2021)．本論文では前者を採用することから，本節では CFAO 型トポロジー・配向最適化に関する先行研究を紹介する．Kim らや Lee らは剛性最大化問題やコンプライアントメカニズム創生問題を対象に繊維体積制約を含んだ離散及び連続の繊維配向角を最適化可能な二次元トポロジー最適化手法を構築した ( (Lee et al, 2018)， (Kim et al, 2021))．Nomura らは配向の最適化について配向テンソル場の要素を設計変数とすることで数値的に安定な最適化手法を構築している (Nomura et al, 2019)．Takezawa らは金属積層造形時に発生する強度の異方性に注目し，直交異方的な Ni 結晶粒の配向を最適化することで等方的で高剛性なラティス構造を設計する手法を構築した (Takezawa et al, 2019)．Schmidt らは静的問題に対して，勾配法と焼きなまし法を組み合わせた配向最適化法を大規模な三次元問題に適用している (Schmidt et al, 2020)．Moter らは 3D プリントされた熱可塑性ポリマーを対象に，応力制約下のトポロジー・配向最適化を行っている (Moter et al, 2021)．Eckrich らは繊維配向は最大主応力方向に向くと仮定しながらも，密度フィルタを介した繊維強化複合材の製造性制約下の剛性最大化を対象とした最適化を行っている (Eckrich et al, 2022)．Huang らは製造制約下のトポロジー・配向最適化に加え，ハミルトン経路に基づいた連続繊維曲線の生成法を提案し，実験的に有効性を実証している (Huang et al, 2022)．しかし，これらの研究は全て確定論的な問題を扱っており，不確実性を考慮したトポロジー・配向同時最適化に関する研究例は少ない．DMO アプローチにおいては，Xu らは荷重の大きさや方向の不確実性を考慮した最適化法を多層複合材にまで展開している (Xu et al, 2019)．CFAO アプローチにおいては，Chu らはやはり荷重に関する不確実性を考慮したトポロジー・配向最適化をクリギング近似モデルを用いて効率的に実行する手法を提案している (Chu et al, 2021) (Svanverg, 1987) と Phase-Field 法 (Takezawa et al, 2010)…”

Section: 異方性を持つ．よって繊維配向を適切に最適化することで，高価な複合材料を最大限効率的に使用できる．unclassified

Topology and orientation optimization of fiber-reinforced materials under fiber manufacturing uncertainty

NOZAWA

Zhang

ZHANG

et al. 2022

Transactions of the JSME (In Japanese)

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Fiber-reinforced composites are currently considered engaging materials by engineers and researchers in automobile, aerospace, robotics, and other related industries and scholars in academics due to their superior mechanical properties.Using the materials as structural materials allows engineers to make lightweight but high-stiff mechanical structures happen in reality. By adopting a structural optimization methodology, they can explore further and bring out the mechanical properties of composites as much as possible to design innovative composites structures. Based on this background, it has already been a hot research topic to establish a method for concurrent optimization of topology and fiber orientation in the structural optimization research field. This optimization method will be more effective in the real world by considering uncertainties that engineers commonly encounter. However, anisotropic topology optimization researches on this motivation are very rare. In the present work, we propose a robust topology and orientation optimization methodology accounting for fiber manufacturing uncertainty, namely orientation uncertainty. The proposed method is built upon the Phase Field and the Method of Moving Asymptotes based SIMP type topology optimization and EOLE-PCE uncertainty quantification. Numerical analysis is done by the Finite Element Method. The effectiveness of the proposed method is validated through the compliance minimization problem and the fundamental eigenfrequency maximization problem.

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“…To restrict the maximum curvature, slope constraints as well as convolution filters can be used, as shown in Greifenstein and Stingl (2016). Nevertheless, CFAO results can be still quite far away from fiber printing paths, with a number of publications studying different postprocessing techniques to obtain continuous fiber paths from orientation fields (see Papapetrou et al 2020;Boddeti et al 2020;Fedulov et al 2021;Fernandes et al 2021). Another notable method to introduce manufacturing constraints into CFAO is detailed in Tian et al (2019), which uses angular constraints similar to slope constraints to mimic gap overlap and curvature constraints for tow-steered composite panels.…”

Section: Introductionmentioning

confidence: 99%

Efficient spline design via feature-mapping for continuous fiber-reinforced structures

Greifenstein

Letournel

Stingl

et al. 2023

Struct Multidisc Optim

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We present a feature-mapping topology optimization approach, in which curved features are parametrized as piecewise linear splines smoothly rounded by arcs. The motivation for our contribution to the tool set of feature-mapping methods is the optimization of structures manufactured by variable angle continuous fiber-reinforced filaments. For this reason, the feature’s geometry should be able to represent long, curved fiber objects satisfying manufacturing constraints, such as minimum turning radius. The proposed model has been chosen with special care for rigorous continuous differentiability, as well as an efficient analytical evaluation of the signed distance field to the spline. The geometrical description and sensitivity analysis of the spline model are developed fully analytically and then mapped to a discretized pseudo-density field for finite element analysis. For the fiber-reinforced material formulation, we also present a new combine step for individual features, in which the best possible angle for the combined features is searched. The model and results are presented in a two-dimensional setting.

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Optimization of parts manufactured using continuous fiber three-dimensional printing technology

Cited by 48 publications

References 27 publications

More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites

More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites

Topology and orientation optimization of fiber-reinforced materials under fiber manufacturing uncertainty

Efficient spline design via feature-mapping for continuous fiber-reinforced structures

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