This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Topology Optimized Design Methodology to Suit Additive Manufacturing Process
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on October 22, 2019 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
The selection of component material and design is an important topic in the manufacturing industry to produce sustainable and competitive products. The efficiency of the system is directly related to the weight of the components in that system. Topology optimization is an optimization method that employs mathematical tools to optimize material distribution in a part to be designed. It is the subfield of structural optimization process which is widely usable in the component development process. Conventional machining, which can be described as subtractive, imposes constraints on a design and can hence be described as a design driven by technology. Additive manufacturing (AM), on the other hand, can be described as technology driven by design. It is possible to manufacture any complex shape without technological constraints using AM. The cons aspect of additive manufacturing is its adaptability to mass production due to its repeatability. Realization of topology optimization through additive manufacturing provides full design freedom for design engineers. This paper discusses the application of topology optimization to parts designed for AM, highlighting the main practical difficulties and opportunities along with the significance of identifying the cost-driven features during the preliminary/conceptual design phase of the component. This article focuses on a design approach with a case study on the redesign of a component by developing a methodology with respect to topology optimization by considering weight and manufacturability as constraints. The structural optimization work is carried out in commercial software Altair Solidthinking (Inspire) and ANSYS. The study results of structural analysis show that topology optimization is a powerful design technique to reduce the weight of a product while maintaining the design requirements.
CitationVemula, S., Naidu, B., Chandrasheker, B., Mylapalli, K. et al., "Topology Optimized Design Methodology to Suit Additive Manufacturing Process," SAE Technical Paper 2019-01-2597, 2019.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
|[Unnamed Dataset 4]|
|[Unnamed Dataset 5]|
- SAE International , “UNS on the Web; Applications of Additive Manufacturing,” https://www.tctmagazine.com/3d-printing-news/additive-manufacturing-can-lower-aircraft-building-and-oper, accessed Oct. 2018.
- Hailu, S.G., Dereje Engida, W., and Fakhruldin Mohd, H. , “A Comparative Study on Stress and Compliance Based Structural Topology Optimization,” IOP Conference Series: Materials Science and Engineering 241(1):012003, 2017, IOP Publishing.
- Deaton, J.D. and Grandhi, R.V. , “A Survey of Structural and Multidisciplinary Continuum Topology Optimization: Post 2000,” Structural and Multidisciplinary Optimization 49(1):1-38, 2014.
- Patel, N.M., Tillotson, D., Renaud, J.E., Tovar, A. et al. , “Comparative Study of Topology Optimization Techniques,” AIAA Journal 46(8):1963-1975, 2008.
- Bendsoe, M.P. and Kikuchi, N. , “Generating Optimal Topologies in Structural Design Using a Homogenization Method,” Computer Methods in Applied Mechanics and Engineering 71(2):197-224, 1988.
- Yang, R.J. and Chuang, C.H. , “Optimal Topology Design Using Linear Programming,” Computers & Structures 52(2):265-275, 1994.
- Rozvany, G.I.N. , “Aims, Scope, Methods, History and Unified Terminology of Computer-Aided Topology Optimization in Structural Mechanics,” Structural and Multidisciplinary Optimization 21(2):90-108, 2001.
- Min, S., Kikuchi, N., Park, Y.C., Kim, S. et al. , “Optimal Topology Design of Structures under Dynamic Loads,” Structural Optimization 17(2-3):208-218, 1999.
- Kaya, N., Karen, I., and Öztürk, F. , “Re-Design of a Failed Clutch Fork Using Topology and Shape Optimisation by the Response Surface Method,” Materials & Design 31(6):3008-3014, 2010.
- Shenoy, P.S. and Fatemi, A. , “Connecting Rod Optimization for Weight and Cost Reduction,” SAE Trans. 523-530, 2005.
- Schäfer, C. and Finke, E. , “Shape Optimisation by Design of Experiments and Finite Element Methods - An Application of Steel Wheels,” Structural and Multidisciplinary Optimization 36(5):477-491, 2008.
- Mok, J. , “Design of a Variable Ratio Brake Pedal,” Department of Mechanical and Industrial Engineering, University of Toronto, 2007.
- Sudin, M.N., Ramli, F.R., Shamsuddin, S.A., Tahir, M.M. et al. , “Redesign of Automotive Brake Pedal Based on Castability Analysis,” Proceedings of Mechanical Engineering Research Day 2015:45-46, 2015.
- Di Sabatino, M. and Arnberg, L. , “Castability of Aluminium Alloys,” Transactions of the Indian Institute of Metals 62(4-5):321-325, 2009.
- Orme, M., Madera, I., Gschweitl, M., and Ferrari, M. , “Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware,” Designs 2(4):51, 2018.
- Yan, C., Hao, L., Hussein, A., Bubb, S.L. et al. , “Evaluation of Light-Weight AlSi10Mg Periodic Cellular Lattice Structures Fabricated via Direct Metal Laser Sintering,” Journal of Materials Processing Technology 214(4):856-864, 2014.
- Meske, R., Sauter, J., and Schnack, E. , “Nonparametric Gradient-Less Shape Optimization for Real-World Applications,” Structural and Multidisciplinary Optimization 30(3):201-218, 2005.
- Larsson, R. , “Methodology for Topology and Shape Optimization: Application to a Rear Lower Control Arm,” Department of Applied Mechanics Chalmers University of Technology, Goteborg, 2016.
- “ANSYS APDL 18.2 User Guide,” 2013.
- “Altair Solidthinking Inspire User Manual Release 8.0,” 2009.
- SAE International , “UNS on the Web; AISI 1018 Material Properties,” http://www.matweb.com/search/DataSheet.aspx?MatGUID=3a9cc570fbb24d119f08db22a53e2421&ckck=1, accessed Apr. 2019.