Topology Optimization System for Additive Manufacturing Orientation
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Solution Overview
Problem
Current additive manufacturing techniques for producing metal parts in aerospace applications face challenges in achieving optimal mechanical properties and specific strength due to limitations in topology optimization and material anisotropy, leading to suboptimal part design and production orientation.
Innovation Solution
A topology optimization system that utilizes a processor unit to assign mechanical properties to unit design cells based on angle values, determining the optimum production orientation and angle for additive manufacturing by matching test data from specimens produced at different angles, and using von Mises failure criterion to calculate safety coefficients and strain energies, thereby optimizing part design for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If topology optimization is performed without considering material anisotropy and production orientation, then the design process is simpler and faster, but the mechanical properties and specific strength of the produced parts are suboptimal
Solution Approach 1:
The system performs preliminary mechanical testing of specimens produced at different angles to the build plate, storing the results in a database. This preliminary action captures material anisotropy characteristics before the actual topology optimization, enabling the optimization algorithm to account for directional mechanical properties without increasing the complexity of the optimization process itself.
Solution Approach 2:
The system establishes a feedback loop where test data from specimens produced at various angles is fed into the topology optimization algorithm. The algorithm uses this feedback to assign direction-dependent mechanical properties to unit design cells, iteratively improving the mechanical properties of the optimized part while the system manages complexity through automated data processing.
2Measurement precision
If specimens are tested at multiple angles to capture anisotropic properties, then more accurate mechanical property data is obtained, but the testing and data collection process becomes more complex
Solution Approach 1:
The testing process is segmented into discrete angular orientations (e.g., 0°, 45°, 90°) relative to the build plate. Specimens are tested at each segment separately, and the results are stored in a database with angle information. This segmentation allows comprehensive anisotropic characterization while managing testing complexity through systematic organization.
Solution Approach 2:
The system varies the angular parameter of specimen orientation relative to the build plate to capture mechanical property variations. By systematically changing this single parameter (angle) while keeping other testing conditions constant, the system achieves precise measurement of anisotropic properties without unnecessarily complicating the testing setup.
3Strength
If the production orientation is optimized based on anisotropic material properties, then parts with higher specific strength are produced, but the determination of optimum orientation requires complex analysis
Solution Approach 1:
The system replaces complex manual mechanical analysis with a computational algorithm that automatically processes test data from specimens at different angles. The processor unit assigns mechanical properties to unit design cells based on their orientation relative to the build plate, using the stored test data. This substitution of mechanical calculation with automated computational processing reduces the difficulty of determining optimum production orientation.
Data Source
AI summary
The present invention relates to at least one part (P) produced by an additive manufacturing method; a table (2) which allows production of a part (P) thereon; at least one digital model (3) created for the purpose of three-dimensional part (P) analysis and/or design in a virtual environment; a plurality of unit design cells (4) that allow the digital model (3) to be created; at least one processor unit (5) that allows creation of a digital model (3) from the unit design cells (4); a plurality of specimens (S), each produced by the manufacturer in a different direction and/or position on the table (2); and at least one database (6) which is created with mechanical property data obtained from the specimens (S).