Integrated component-support topology optimization for additive manufacturing with post-machining

Integrated component-support topology optimization for additive manufacturing with post-machining

Langelaar, Matthijs (TU Delft Computational Design and Mechanics)

2019

Purpose: The purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements. Design/methodology/approach: An integrated topology optimization is proposed using two density fields: one describing the design and another defining the support layout. Using a simplified AM process model, critical overhang angle restrictions are imposed on the design. Through additional load cases and constraints, sufficient stiffness against subtractive machining loads is enforced. In addition, a way to handle non-design regions in an AM setting is introduced. Findings: The proposed approach is found to be effective in producing printable optimized geometries with adequate stiffness against machining loads. It is shown that post-machining requirements can affect optimal support structure layout. Research limitations/implications: This study uses a simplified AM process model based on geometrical characteristics. A challenge remains to integrate more detailed physical AM process models to have direct control of stress, distortion and overheating. Practical implications: The presented method can accelerate and enhance the design of high performance parts for AM. The consideration of post-print aspects is expected to reduce the need for design adjustments after optimization. Originality/value: The developed method is the first to combine AM printability and machining loads in a single topology optimization process. The formulation is general and can be applied to a wide range of performance and manufacturability requirements.

Additive manufacturing
Design
Design for manufacturing
Optimization
Overhang
Post-machining
Rapid manufacturing
Subtractive machining
Support structures
Topology optimization

http://resolver.tudelft.nl/uuid:f51306b3-3116-4cc7-bdac-cd409df4e99f

https://doi.org/10.1108/RPJ-12-2017-0246

1355-2546

Rapid Prototyping Journal: the international journal for research on additive manufacturing technologies and rapid product development, 25 (2), 255-265

Institutional Repository

journal article

© 2019 Matthijs Langelaar