Topology optimization and additive manufacturing for aerospace components

Berrocal, Laura; Fernández, Rosario; González, S.; Periñán, Antonio; Tudela, Santos; Vilanova, Jorge; Rubio, Luis Pallarés; Márquez, Jose Manuel Martín; Guerrero, Javier; Lasagni, Fernando

doi:10.1007/s40964-018-0061-3

Cited by 50 publications

(22 citation statements)

References 13 publications

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“…Generate optimized lattice and mixed solid -lattice structures, visualize simulation results in 3D, and export lattice designs in a .stl file format for 3D printing. View and interactively assign loads to load cases and import / export design loads in .csv file format with the new Load Cases Table. A recipe of the operation for a final optimal design is then presented to the manufacturing engineers thus saving them time and cost optimal design is then presented to the manufacturing engineers thus saving them time and cost [2], [5], [8]. Design for additive manufacturing with overhang shape controls to help reduce overhangs to create more self-supporting structures Today, die design standards are used to design the structure of die components.…”

Section: Methodsmentioning

confidence: 99%

Topology Optimization of Automotive sheet metal part using Altair Inspire

Ferede

2020

IJEMS

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In an optimization problem, different candidate solutions are compared with each other, and then the best or optimal solution is obtained which means that solution quality is fundamental. Topology optimization is used at the concept stage of design. It deals with the optimal distribution of material within the structure. Altair Inspire software is the industry's most powerful and easy-to-use Generative Design/Topology Optimization and rapid simulation solution for design engineers. In this paper Topology optimization is applied using Altair inspire to optimize the Sheet metal Angle bracket. Different results are conducted the better and final results are fulfilling the goal of the paper which is minimizing the mass of the sheet metal part by 65.9% part and Maximizing the stiffness with Better Results of Von- Miss Stress Analysis, Displacement, and comparison with different load cases. This can lead to reduced costs, development time, material consumption, and product less weight.

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Section: Methodsmentioning

confidence: 99%

Topology Optimization of Automotive sheet metal part using Altair Inspire

Ferede

2020

IJEMS

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“…The most common technique to solve the optimization problem is the Solid Isotropic Microstructure with Penalization (SIMP), which assumes a continuous function density as the design variable. This method has been employed for different applications such as structural [ 36 ], aerospace [ 37 ], architectural design [ 38 ] and medical applications [ 39 , 40 , 41 ]. The optimization process initiates by discretizing the design domain into a set of elements, assigning to each element a density (

) value of 0 or 1 (0 density means a void and 1 means a solid element) [ 40 , 41 ].…”

Section: Modeling and Simulationmentioning

confidence: 99%

Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

et al. 2021

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The use of external fixation devices is considered a valuable approach for the treatment of bone fractures, providing proper alignment to fractured fragments and maintaining fracture stability during the healing process. The need for external fixation devices has increased due to an aging population and increased trauma incidents. The design and fabrication of external fixations are major challenges since the shape and size of the defect vary, as well as the geometry of the human limb. This requires fully personalized external fixators to improve its fit and functionality. This paper presents a methodology to design personalized lightweight external fixator devices for additive manufacturing. This methodology comprises data acquisition, Computer tomography (CT) imaging analysis and processing, Computer Aided Design (CAD) modelling and two methods (imposed predefined patterns and topology optimization) to reduce the weight of the device. Finite element analysis with full factorial design of experiments were used to determine the optimal combination of designs (topology optimization and predefined patterns), materials (polylactic acid, acrylonitrile butadiene styrene, and polyamide) and thickness (3, 4, 5 and 6 mm) to maximize the strength and stiffness of the fixator, while minimizing its weight. The optimal parameters were found to correspond to an external fixator device optimized by topology optimization, made in polylactic acid with 4 mm thickness.

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“…Laser Powder Bed Fusion (LPBF) of Ti-6Al-4V offers considerable potential for lightweight applications. Combined with advanced design approaches such as topology optimization significant weight reduction is achievable with LPBF, such as 19-63% in the study by [1] with four aerospace use cases. The lightweight design is often associated with complex part geometries.…”

Section: Introductionmentioning

confidence: 97%

Geometry Effect on Microstructure and Mechanical Properties in Laser Powder Bed Fusion of Ti-6Al-4V

Munk

Breitbarth

Siemer

et al. 2022

Metals

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Laser Powder Bed Fusion (LPBF) of Ti-6Al-4V enables the manufacturing of complex parts for lightweight applications. The emerging microstructure in the LPBF process and thus the mechanical properties are defined by the thermal cycles, which are locally variable for complex geometries. Predictions of local mechanical properties by simulation would reduce the development time of new applications drastically but are today not possible on part scale, so new part applications must be qualified experimentally at great effort. In this study, representative geometry sections were transferred into a simplified sample shape to mechanically characterize different geometry-dependent microstructures. In areas exposed to comparatively increased heat input over time, a lamellar α + β microstructure with β fraction up to 20% was measured in contrast to the common martensitic α′ microstructure of LPBF-manufactured Ti-6Al-4V, resulting in reduced tensile strength and fatigue life. For the first time, a correlation was successfully established between ultimate tensile strength of multiple geometries and the corresponding temperature–time cycles. With reduced computational effort by use of simplifying assumptions in the simulation, this correlation model can theoretically be applied to the part level. This work has laid the foundation for the simulation-based prediction of mechanical properties for entire parts manufactured with LPBF.

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Topology optimization and additive manufacturing for aerospace components

Cited by 50 publications

References 13 publications

Topology Optimization of Automotive sheet metal part using Altair Inspire

Topology Optimization of Automotive sheet metal part using Altair Inspire

Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

Geometry Effect on Microstructure and Mechanical Properties in Laser Powder Bed Fusion of Ti-6Al-4V

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