Topology Optimization of the Clutch Lever Manufactured by Additive Manufacturing

Mikulíková, Aleksandra; Měsíček, Jakub; Karger, Jan; Hajnyš, Jiří; Ma, Quoc-Phu; Slíva, Aleš; Smiraus, Jakub; Srnicek, David; Cienciala, Samuel; Pagáč, Marek

doi:10.3390/ma16093510

Cited by 3 publications

(1 citation statement)

References 41 publications

(49 reference statements)

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“…Considering a design space and a set of constraints (such as loads and BCs), topology optimization is an example of the computational approach that makes it possible to determine the best material distribution within that space [ 51 , 52 ]. The overall weight of the intended product can be significantly reduced while still retaining the appropriate strength and rigidity with the application of topology optimization in the design process [ 53 ].…”

Section: Methodsmentioning

confidence: 99%

Finite Element Analysis of Upper Limb Splint Designs and Materials for 3D Printing

et al. 2023

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Three-dimensional (3D) printed splints must be lightweight and adequately ventilated to maximize the patient’s convenience while maintaining requisite strength. The ensuing loss of strength has a substantial impact on the transformation of a solid splint model into a perforated or porous model. Thus, two methods for making perforations—standard approach and topological optimization—are investigated in this study. The objective of this research is to ascertain the impact of different perforation shapes and their distribution as well as topology optimization on the customized splint model. The solid splint models made of various materials have been transformed into porous designs to evaluate their strength by utilizing Finite Element (FE) simulation. This study will have a substantial effect on the designing concept for medical devices as well as other industries such as automobiles and aerospace. The novelty of the research refers to creating the perforations as well as applying topology optimization and 3D printing in practice. According to the comparison of the various materials, PLA had the least amount of deformation and the highest safety factor for all loading directions. Additionally, it was shown that all perforation shapes behave similarly, implying that the perforation shape’s effect is not notably pronounced. However, square perforations seemed to perform the best out of all the perforation shape types. It was also obvious that the topology-optimized hand splint outperformed that with square perforations. The topology-optimized hand splint weighs 26% less than the solid splint, whereas the square-perforated hand splint weighs roughly 12% less. Nevertheless, the user must choose which strategy (standard perforations or topology optimization) to employ based on the available tools and prerequisites.

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Section: Methodsmentioning

confidence: 99%

Finite Element Analysis of Upper Limb Splint Designs and Materials for 3D Printing

et al. 2023

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Application of Surface-Based Smoothing Methods for Topology Optimization Results

Sotola,

Marsalek,

Rybansky

et al. 2024

Int. J. Appl. Mechanics

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Topology optimization (TO) is becoming an essential part of designing new or modifying current parts to improve their properties. A typical problem of TO in structural applications is minimizing compliance with volume (mass) constraints. TO is often complemented by additive manufacturing which allows the printing of complex geometries. Resulting geometries are dependent on the used method, most of the time it is the finite element method. The exported geometry from the optimization procedure, however, tends to have a lot of sharp edges, which causes problems with stress distribution, aesthetics and manufacturing (even if it is additive manufactured). The aim of this paper is to review, apply smoothing techniques on the surface of bodies, Laplacian and Taubin smoothing, and compare the results of smoothing. To fulfill this aim, we developed a smoothing procedure and evaluated the criteria of smoothed-out polymer geometries.

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Weight Factor as a Parameter for Optimal Part Orientation in the L-PBF Printing Process Using Numerical Simulation

Kaščák,

Varga,

Bidulská

et al. 2024

Materials

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The L-PBF process belongs to the most modern methods of manufacturing complex-shaped parts. It is used especially in the automotive, aviation industries, and in the consumer products industry as well. Numerical simulation in the powder sintering process is a means of optimizing time efficiency, accuracy and predicting future errors. It is one of the means to optimize the L-PBF process, which makes it possible to investigate the influence of individual parameters on additive manufacturing. This research makes it possible to predict the correct orientation of a part based on selected criteria, which are assigned a weighting factor in the form of parameters with which the simulation software Simufact Additive can work. Based on these, three possible orientations of the part were analysed with respect to the area of the supporting material, the volume of the supporting material, the number of voxels, and the building risk. Finally, the results of a simulation and the results of the tensile test were compared. From the results of the static tensile test, as well as from the results of the numerical simulation, it was found that better characteristics were achieved for the orientation of part no. 1 compared to orientation of part No. 3.

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Topology Optimization of the Clutch Lever Manufactured by Additive Manufacturing

Cited by 3 publications

References 41 publications

Finite Element Analysis of Upper Limb Splint Designs and Materials for 3D Printing

Finite Element Analysis of Upper Limb Splint Designs and Materials for 3D Printing

Application of Surface-Based Smoothing Methods for Topology Optimization Results

Weight Factor as a Parameter for Optimal Part Orientation in the L-PBF Printing Process Using Numerical Simulation

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