Structural topology optimization subject to overhang angle constraint with overhang length relaxation in additive manufacturing
This paper studies additive manufacturing (AM) oriented structural topology optimization (TO). The minimum compliance design subject to overhang angle constraint with overhang length relaxation and horizontal minimum length control is considered. Although the overhang length relaxation allows additi...
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| Veröffentlicht in: | Science China. Technological sciences Jg. 65; H. 6; S. 1213 - 1231 |
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| Sprache: | Englisch |
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Beijing
Science China Press
01.06.2022
Springer Nature B.V |
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| ISSN: | 1674-7321, 1869-1900 |
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| Abstract | This paper studies additive manufacturing (AM) oriented structural topology optimization (TO). The minimum compliance design subject to overhang angle constraint with overhang length relaxation and horizontal minimum length control is considered. Although the overhang length relaxation allows additional flexibility for AM product design, there have been very limited studies on it. This paper elucidates that the overhang angle constraint we proposed can identify the lower boundary element that violates the overhang angle constraint. Taking advantage of this fact, we achieve the overhang length relaxation by specifying that the volume fraction of the elements that violate the overhang angle constraint in each local area of the design domain is less than a specified upper bound. A formula for estimating the maximum allowable overhang length of this method is proposed and verified. The horizontal minimum length constraint is also employed in this paper. While controlling the horizontal length size of the structural member, this constraint together with the overhang angle constraint with overhang length relaxation suppresses the hanging feature. The gradient-based optimization algorithm method of moving asymptotic (MMA) is used to solve the TO formulation. Numerical examples show the effectiveness of this method. It is observed that the new constraint alleviates the main issues of traditional overhang angle constraints, i.e., gray element issue, stress concentration issue, and shattered structure issue. Compared with the strict traditional overhang angle constraint, the new formulation reduces structural compliance. |
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| AbstractList | This paper studies additive manufacturing (AM) oriented structural topology optimization (TO). The minimum compliance design subject to overhang angle constraint with overhang length relaxation and horizontal minimum length control is considered. Although the overhang length relaxation allows additional flexibility for AM product design, there have been very limited studies on it. This paper elucidates that the overhang angle constraint we proposed can identify the lower boundary element that violates the overhang angle constraint. Taking advantage of this fact, we achieve the overhang length relaxation by specifying that the volume fraction of the elements that violate the overhang angle constraint in each local area of the design domain is less than a specified upper bound. A formula for estimating the maximum allowable overhang length of this method is proposed and verified. The horizontal minimum length constraint is also employed in this paper. While controlling the horizontal length size of the structural member, this constraint together with the overhang angle constraint with overhang length relaxation suppresses the hanging feature. The gradient-based optimization algorithm method of moving asymptotic (MMA) is used to solve the TO formulation. Numerical examples show the effectiveness of this method. It is observed that the new constraint alleviates the main issues of traditional overhang angle constraints, i.e., gray element issue, stress concentration issue, and shattered structure issue. Compared with the strict traditional overhang angle constraint, the new formulation reduces structural compliance. |
| Author | Zhang, KaiQing Cheng, GengDong Wang, Yu |
| Author_xml | – sequence: 1 givenname: KaiQing surname: Zhang fullname: Zhang, KaiQing organization: Department of Engineering Mechanics, Dalian University of Technology – sequence: 2 givenname: GengDong surname: Cheng fullname: Cheng, GengDong email: chenggd@dlut.edu.cn organization: State Key Laboratory of Structural Analysis for Industrial Equipment, Dalian University of Technology – sequence: 3 givenname: Yu surname: Wang fullname: Wang, Yu organization: Department of Engineering Mechanics, Dalian University of Technology |
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| CitedBy_id | crossref_primary_10_1016_j_istruc_2024_107359 crossref_primary_10_1007_s11430_024_1526_3 crossref_primary_10_1007_s00158_023_03732_4 crossref_primary_10_1007_s00158_024_03808_9 crossref_primary_10_1016_j_tws_2023_111439 crossref_primary_10_1007_s11431_022_2198_4 crossref_primary_10_1088_1361_665X_ada07d crossref_primary_10_1016_j_addma_2023_103919 |
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| Keywords | overhang angle constraint design for manufacturability additive manufacturing topology optimization overhang length relaxation |
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| SubjectTerms | Additive manufacturing Algorithms Asymptotic methods Design optimization Engineering Manufacturing Optimization Product design Stress concentration Structural members Topology optimization Upper bounds |
| Title | Structural topology optimization subject to overhang angle constraint with overhang length relaxation in additive manufacturing |
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