Fatigue Behavior of Metallic Components Obtained by Topology Optimization for Additive Manufacturing

Abstract

The main goal of the present research is to propose an integrated methodology to address the fatigue performance of topology optimized components, produced by additive manufacturing. The main steps of the component design will be presented, specially the methods and parameters applied to the topology optimization and the post-smoothing process. The SIMP method was applied in order to obtain a lighter component and a suitable stiffness for the desired application. In addition, since residual stresses are intrinsic to every metallic additive manufacturing process, the influence of those stresses will be also analyzed. The Laser Powder Bed Fusion was numerically simulated aiming at evaluating the residual stresses the workpiece during the manufacturing process and to investigate how they could influence the fatigue behavior of the optimized component. The effect of the built orientation of the workpiece on the residual stresses at some selected potential critical points are evaluated. The final design solution presented a stiffness/volume ratio nearly 6 times higher when compared to the initial geometry. By choosing the built orientation, it is possible impact favorably in the fatigue life of the component.

Experiments and numerical simulation of wire and arc additive manufactured steel materials

“…Additive manufacturing (AM), also referred to as 3D printing, is a technology that forms three-dimensional objects by placing successive layers of raw materials. AM is becoming popular in the construction sector [1][2][3][4][5] attributing to its rapid prototyping advantages. Seven types of distinct processes of AM processes are recognized by ISO/ASTM 52,900 [6] as follows: material extrusion, material jetting, binder jetting, powder bed fusion, directed energy deposition, vat photopolymerization, and sheet lamination.…”

Geometrical Accuracy Analysis of Ti-6Al-4V Trusses Manufactured by Electron Beam Melting Process

“…This resulted in part distortion that compromised the powder deposition and melting stages in the subsequent layers. A strong dependence of the residual stresses and the yield strength on the building orientation was also found in [43] and [44], respectively.…”

Significant Advancements in Numerical Simulation of Fatigue Behavior in Metal Additive Manufacturing-Review

“…The optimization methodology proposed was able to find an efficient geometry, and fulfill the design requirements [92]. The optimization was proved to be efficient by optimizing the volume and the mass of the component was 12.53% of the initial domain.…”