Topology and fibre orientation simultaneous optimisation: A design methodology for fibre-reinforced composite components

Caivano, Riccardo; Tridello, Andrea; Paolino, Davide Salvatore; Chiandussi, Giorgio

doi:10.1177/1464420720934142

Cited by 13 publications

(10 citation statements)

References 34 publications

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“…The effect of infill density on caries in a PETG part manufactured using the fusion deposition modeling technique was explored. The mechanical properties were found to be significantly influenced by infill structures and density [ 1 , 2 ]. The effect of infill patterns on the mechanical properties was investigated in lightweight 3D-printed PLA cellular parts; the variation of relative flexural modulus concerning the relative density of the material was exhibited in the research.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Tensile Properties of Different Infill Pattern Structures of 3D-Printed PLA Polymers: Analysis and Validation Using Finite Element Analysis in ANSYS

Ganeshkumar¹,

Kumar

Magarajan

et al. 2022

Materials

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The advancement of 3D-printing technology has ushered in a new era in the production of machine components, building materials, prototypes, and so on. In 3D-printing techniques, the infill reduces the amount of material used, thereby reducing the printing time and sustaining the aesthetics of the products. Infill patterns play a significant role in the property of the material. In this research, the mechanical properties of specimens are investigated for gyroid, rhombile, circular, truncated octahedron, and honeycomb infill structures (hexagonal). Additionally, the tensile properties of PLA 3D-printed objects concerning their infill pattern are demonstrated. The specimens were prepared with various infill patterns to determine the tensile properties. The fracture of the specimen was simulated and the maximum yield strengths for different infill structures and infill densities were determined. The results show the hexagonal pattern of infill holds remarkable mechanical properties compared with the other infill structures. Through the variation of infill density, the desired tensile strength of PLA can be obtained based on the applications and the optimal weight of the printed parts.

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Section: Introductionmentioning

confidence: 99%

Investigation of Tensile Properties of Different Infill Pattern Structures of 3D-Printed PLA Polymers: Analysis and Validation Using Finite Element Analysis in ANSYS

Ganeshkumar¹,

Kumar

Magarajan

et al. 2022

Materials

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“…equal to the product of the Young’s modulus E and the thermal expansion coefficient α,β=Eα), k is the thermal conduction coefficient, bold-italicσ is the stress tensor, bold-italicF is the vector of internal forces, H is the internal generated heat, and bold0 is the null vector. Applying the variational methodology as done in Caivano et al., 22 by integrating equation (2) in the domain Ω, it is possible to obtain the weak expression of the potential energy of the system. In particular, the solution of a thermomechanical topology optimization problem can be achieved by implementing the weak expression of the potential energy by excluding differential terms.…”

Section: Methodsmentioning

confidence: 99%

“…Applying the variational methodology as done in Caivano et al, 22 by integrating equation (2) in the domain X, it is possible to obtain the weak expression of the potential energy of the system. In particular, the solution of a thermomechanical topology optimization problem can be achieved by implementing the weak expression of the potential energy by excluding differential terms.…”

Section: Thermostructural Topology Optimization: the Optimality Criteriamentioning

confidence: 99%

A new methodology for thermostructural topology optimization: Analytical definition and validation

Caivano

Tridello

Codegone

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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In the last few years, the rapid diffusion of components produced through additive manufacturing processes has boosted the research on design methodologies based on topology optimization algorithms. Structural topology optimization is largely employed since it permits to minimize the component weight and maximize its stiffness and, accordingly, optimize its resistance under structural loads. On the other hand, thermal topology optimization has been less investigated, even if in many applications, such as turbine blades, engines, heat exchangers, thermal loads have a crucial impact. Currently, structural and thermal optimizations are mainly considered separately, despite the fact that they are both present and coupled in components in service condition. In the present paper, a novel methodology capable of defining the optimized structure under simultaneous thermomechanical constraints is proposed. The mathematical formulation behind the optimization algorithm is reported. The proposed methodology is finally validated on literature benchmarks and on a real component, confirming that it permits to define the topology, which presents the maximized thermal and mechanical performance.

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“…There are also iterative variants. For example, Caivano et al [2020] proposed iterating between calculating the principal stress direction and updating the material distribution until convergence. While mainly concentrating on orientation optimization, some approaches do ultimately generate fiber paths.…”

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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Topology and fibre orientation simultaneous optimisation: A design methodology for fibre-reinforced composite components

Cited by 13 publications

References 34 publications

Investigation of Tensile Properties of Different Infill Pattern Structures of 3D-Printed PLA Polymers: Analysis and Validation Using Finite Element Analysis in ANSYS

Investigation of Tensile Properties of Different Infill Pattern Structures of 3D-Printed PLA Polymers: Analysis and Validation Using Finite Element Analysis in ANSYS

A new methodology for thermostructural topology optimization: Analytical definition and validation

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

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