Knowledge Management for Topological Optimization Integration in Additive Manufacturing

Abstract

Engineering design optimization of mechanical structures is nowadays essential in the mechanical industry (automotive, aeronautics, etc.). To remain competitive in the globalized world, it is necessary to create and design structures that, in addition to complying specific mechanical performance, should be less expensive. Engineers must then design parts or assemblies that are a better compromise between mechanical and functional performance, weight, manufacturing costs, and so forth. In this context Additive Manufacturing (AM) process offers the possibility to avoid tools and manufacture directly the part. There are numerous technologies which are using different kind of material. For each of these, there are at least two materials: the production material and the support one. Support material is, in most cases, cleaned and becomes a manufacturing residue. Improving the material volume and the global mass of the product is an essential aim surrounding the integration of simulation in additive manufacturing process. Moreover, the layer-by-layer technology of additive manufacturing allows the design of innovative objects, and the use of topological optimization in this context can create a very interesting combination. The purpose of our paper is to present the knowledge management of an AM trade oriented tool which integrated the topological optimization of parts and internal patterns.

The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment

“…The main advantage of this process over conventional manufacturing methods is the facility to create lightweight parts, such as those which result from topology optimisation [1,2] or include lattice structures [3][4][5] to replace bulk solids. SLM saves resources, reduces waste and carbon footprint [6,7].…”

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality

“…Drastic weight reduction can be achieved by several methods, such as topology optimisation [3,4] or replacing a bulk of solid material with latticed structures [5,6]. AM has the potential to fulfil demands for cost and design-to-manufacturing time reduction through saving on raw materials and replacing a series of production processes with a single step process.…”

Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using X-ray computed tomography

“…These include a level of design freedom which is unconstrained by the limitations of tool accessibility [1,2]. Complex shapes, including those that stem from the use of weight saving topology optimisation [3][4][5][6] or lattice structures [7][8][9][10][11][12][13][14][15][16] can be manufactured with no additional cost or energy expenditure compared to traditional forms; in many cases the advantages of AM lie in its facility to produce shapes that are not achievable by other means. Additional benefits include low material wastage and a reduction of the number of manufacturing steps [1,2,17,18].…”