Design and Development of an Additive Manufactured Component by Topology Optimisation

Walton, Dan; Moztarzadeh, Hadi

doi:10.1016/j.procir.2017.03.027

Cited by 61 publications

(35 citation statements)

References 6 publications

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“…The AM engineering cycle requires several steps, namely design optimization, manufacturing and inspection. Recently, Walton and Moztarzadeh [73] presented a classic case study, where the design optimization cycle was performed using Topology Optimization (TO), compliance minimization was the goal and mass and stress were the constraints. Moreover, a member size limitation of 6 mm (min.)…”

Section: Am Design Optimizationmentioning

confidence: 99%

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Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

Barroqueiro

Andrade‐Campos

Valente

et al. 2019

JMMP

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Additive Manufacturing (AM) is the forefront of advanced manufacturing technologies and has the potential to revolutionize manufacturing, with a dramatic change in the design and project paradigms. A comprehensive review of existent metal AM processes, processable materials, respective defects and inspection methods (destructive and non-destructive) is presented in a succinct manner. Particularly, the AM design optimization methodologies are reviewed and their threats and constraints discussed. Finally, an aerospace industry case study is presented and several cost-effective examples are enumerated.

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Section: Am Design Optimizationmentioning

confidence: 99%

“…Taking into consideration the results of TO, the part was redesigned and manufactured. Engineering cycle of an AM part: (a) presentation of the design domain and boundary conditions; (b) density maps of TO, considering the threshold at 0.25; (c) AM part still with the support structures; (d) machined AM part; and (e) its X-Ray inspection[73].…”

mentioning

confidence: 99%

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

Barroqueiro

Andrade‐Campos

Valente

et al. 2019

JMMP

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“…have designed and developed the some methods like utilizing Electron-Beam-Melting method which includes topology-optimization. And based on the research he concluded that geometry could be conducted while topology optimization is used to decrease any requirement for supporting structures like processing time, cost of manufacturing [5]. In mechanical field, GD is not only Topology Optimization (TO), which provides plausible topologies can be optimized [3], and a unique method, however, it has different modules to reach to the optimal design using the Computer Aided Design software, based on the design objectives, some parameters need to be considered [2].…”

Section: Introductionmentioning

confidence: 99%

Generative Design of Articulated Rod of Radial Engine

Rai,

Keawmuang,

Variyavwala

et al. 2021

IJEMS

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The constant need for improvement drives humans to look for the best possible option in every field. Computer Aided Design (CAD) is no exception, to follow the best method of designing a product and finalizing it, researchers came up with an idea to generate multiple designs using fixed input values and finalizing the most appropriate one. The objective is achieved using an iterative design process based on algorithms by a specific software. Generative design introduces a new experience based on the Integration of machine dynamics in the manufacturing of objects and about experience. In this work generative design method was investigated on an articulated rod, one of the most important components of the rotary engine, to effectively improve the overall working performance of the engine and enhance its performance by decreasing its mass. Since fuel consumption by the machine can be greatly reduced by lowering the mass, so the goal is to minimize the weight of the rod while mechanical characteristics have to be within the acceptable values. Also, finite element analysis (FEA) was investigated on the part as to ensure the reliability of the rod before and after optimization.

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“…The design of a vehicle upright manufactured via metal AM through TO is presented by Walton and Moztarzadeh 25 and Reddy et al 26 and is critically summarized in Plocher and Panesar. 8 In Reddy et al, 26 the minimization of the supporting structures was pursued together with the minimization of the component weight.…”

Section: Introductionmentioning

confidence: 99%

Synergy between topology optimization and additive manufacturing in the automotive field

Mantovani

Barbieri

Giacopini

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article purposes on developing and on re-interpreting the numerical results of a topology optimization for a structural component built via additive manufacturing. A critical appraisal of the optimization results is presented by modeling the feasible component with a holistic approach that merges structural and manufacturing requirements. The procedure is expected to provide a design guideline for similar applications of practical relevance, toward an increase of the right-first-time parts that is required to bring additive manufacturing to its full competitiveness. Topology optimization of a steering upright for a Formula SAE racing car was performed by targeting weight minimization while complying with severe structural constraints, like global and local stiffness performance. Cornering, bumping and braking vehicle conditions were considered. The optimization constraints were evaluated via finite element analysis on a reference component, where the loading conditions were retrieved from telemetry data. The reference part was manufactured by computer numerical control machining from a solid aluminum block. Spurred by the interpretation of the topology optimization predictions, a new upright geometry was designed and validated by calculating its stress field and the possible occurrence of Euler buckling. The new upright was 9% lighter than the reference component. The new geometry was analyzed according to Design for Additive Manufacturing principles to choose the orientation on the build platform and the supports’ location and geometry. The part was successfully manufactured and proved consistent with the application.

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Design and Development of an Additive Manufactured Component by Topology Optimisation

Cited by 61 publications

References 6 publications

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

Generative Design of Articulated Rod of Radial Engine

Synergy between topology optimization and additive manufacturing in the automotive field

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