Generative 3D Shape Optimization for Fatigue Loading Cycles
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Solution Overview
Problem
Current CAD software limitations in generative design for additive and subtractive manufacturing fail to effectively prevent damage from loading cycles, particularly in optimizing fatigue resistance and structural integrity, especially when dealing with multiple materials and complex load cases.
Innovation Solution
A computer-aided design program iteratively modifies 3D shapes based on design criteria, in-use load cases, and material specifications, using numerical simulations to assess stress and strain, and updates the shape through a level-set representation to ensure fatigue safety, converging to a stable solution that prevents damage over defined loading cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If generative design is used to optimize 3D geometry for weight and material efficiency, then weight and material usage are reduced, but fatigue resistance and structural integrity under repeated loading cycles are not adequately ensured
Solution Approach 1:
The patent applies preliminary action by performing fatigue analysis and damage prevention calculations during the generative design phase itself, rather than as a separate subsequent step. The system evaluates fatigue constraints and modifies the 3D geometry iteratively to prevent fatigue damage before manufacturing, ensuring that weight optimization does not compromise structural integrity under repeated loading cycles.
2Reliability
If complex numerical simulations are performed to assess stress and strain for fatigue analysis, then fatigue safety is improved, but computational time and processing resources increase
Solution Approach 1:
The patent implements feedback by using the results of numerical stress and strain simulations to iteratively modify the 3D geometry in the generative design process. The system continuously evaluates fatigue constraints based on simulation results and adjusts the design accordingly, creating a closed-loop process that improves fatigue safety while managing computational resources through targeted iterations rather than exhaustive analysis.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes. A method includes obtaining a design space for a modeled object, one or more design criteria, one or more in-use load cases, and one or more specifications of material, wherein the design criteria comprise a required number of loading cycles for the modeled object; iteratively modifying a generatively designed three dimensional shape of the modeled object, comprising: performing numerical simulation of the modeled object, finding a maximized stress or strain element for each of the one or more in-use load cases, determining an expected number of loading cycles for each of the one or more in-use load cases, redefining a fatigue safety factor inequality constraint for the modeled object, computing shape change velocities in accordance with at least the fatigue safety factor inequality constraint, and updating the level-set representation.