Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Li, Bo; Shen, Ciming

doi:10.3390/polym14142807

Cited by 11 publications

(2 citation statements)

References 36 publications

(46 reference statements)

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“…There have also been efforts to create structures using topology optimization. Li et al used an FCC lattice structure as the base cell and created a bigger structure and used topology optimization to increase the strut diameters at localized regions based on the loading condition and demonstrated increased rigidity based on the application [21]. These cases demonstrated the fact that by strategically adding material, we can achieve higher lightweighting compared to just using basic strut-based lattices.…”

Section: Introductionmentioning

confidence: 99%

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

Ghosh,

D’Souza

2024

Polymers

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The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

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Section: Introductionmentioning

confidence: 99%

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

Ghosh,

D’Souza

2024

Polymers

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“…Boolean operations on geometric models are a core element in the field of computeraided design and graphics, and are the basic algorithms for constructing solid geometric models. They are used in the construction industry [5], manufacturing industry [6,7], computer vision [8][9][10], graphics [11,12], and other scientific research fields [13,14]. Boolean operations are needed to combine and truncate geometric models to generate complex 3D models; therefore, Boolean operations have important research significance.…”

Section: Introductionmentioning

confidence: 99%

Simple and Robust Boolean Operations for Triangulated Surfaces

et al. 2023

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Boolean operations on geometric models are important in numerical simulation and serve as essential tools in the fields of computer-aided design and computer graphics. The accuracy of these operations is heavily influenced by finite precision arithmetic, a commonly employed technique in geometric calculations, which introduces numerical approximations. To ensure robustness in Boolean operations, numerical methods relying on rational numbers or geometric predicates have been developed. These methods circumvent the accumulation of rounding errors during computation, thus preserving accuracy. Nonetheless, it is worth noting that these approaches often entail more intricate operation rules and data structures, consequently leading to longer computation times. In this paper, we present a straightforward and robust method for performing Boolean operations on both closed and open triangulated surfaces. Our approach aims to eliminate errors caused by floating-point operations by relying solely on entity indexing operations, without the need for coordinate computation. By doing so, we ensure the robustness required for Boolean operations. Our method consists of two main stages: (1) Firstly, candidate triangle intersection pairs are identified using an octree data structure, and then parallel algorithms are employed to compute the intersection lines for all pairs of triangles. (2) Secondly, closed or open intersection rings, sub-surfaces, and sub-blocks are formed, which is achieved entirely by cleaning and updating the mesh topology without geometric solid coordinate computation. Furthermore, we propose a novel method based on entity indexing to differentiate between the union, subtraction, and intersection of Boolean operation results, rather than relying on inner and outer classification. We validate the effectiveness of our method through various types of Boolean operations on triangulated surfaces.

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Inverse Design of Energy‐Absorbing Metamaterials by Topology Optimization

et al. 2022

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Compared with the forward design method through the control of geometric parameters and material types, the inverse design method based on the target stress‐strain curve is helpful for the discovery of new structures. This study proposes an optimization strategy for mechanical metamaterials based on a genetic algorithm and establishes a topology optimization method for energy‐absorbing structures with the desired stress‐strain curves. A series of structural mutation algorithms and design‐domain‐independent mesh generation method are developed to improve the efficiency of finite element analysis and optimization iteration. The algorithm realizes the design of ideal energy‐absorbing structures, which are verified by additive manufacturing and experimental characterization. The error between the stress‐strain curve of the designed structure and the target curve is less than 5%, and the densification strain reaches 0.6. Furthermore, special attention is paid to passive pedestrian protection and occupant protection, and a reasonable solution is given through the design of a multiplatform energy‐absorbing structure. The proposed topology optimization framework provides a new solution path for the elastic‐plastic large deformation problem that is unable to be resolved by using classical gradient algorithms or genetic algorithms, and simplifies the design process of energy‐absorbing mechanical metamaterials.

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Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Cited by 11 publications

References 36 publications

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

Simple and Robust Boolean Operations for Triangulated Surfaces

Inverse Design of Energy‐Absorbing Metamaterials by Topology Optimization

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