Exploiting Additive Manufacturing Infill in Topology Optimization for Improved Buckling Load

By Anders Clausen, Niels Aage, Ole Sigmund. 2016

233 citations recorded by the source corpus.

ABSTRACT Additive manufacturing (AM) permits the fabrication of functionally optimized components with high geometrical complexity. The opportunity of using porous infill as an integrated part of the manufacturing process is an example of a unique AM feature. Automated design methods are still incapable of fully exploiting this design freedom. In this work, we show how the so-called coating approach to topology optimization provides a means for designing infill-based components that possess a strongly improved buckling load and, as a result, improved structural stability. The suggested approach thereby addresses an important inadequacy of the standard minimum compliance topology optimization approach, in which buckling is rarely accounted for; rather, a satisfactory buckling load is usually assured through a post-processing step that may lead to sub-optimal components. The present work compares the standard and coating approaches to topology optimization for the MBB beam benchmark case. The optimized structures are additively manufactured using a filamentary technique. This experimental study validates the numerical model used in the coating approach. Depending on the properties of the infill material, the buckling load may be more than four times higher than that of solid structures optimized under the same conditions.

Subfields: Building and Construction, Civil and Structural Engineering, Industrial and Manufacturing Engineering

View Paper: https://www.semanticscholar.org/paper/157b328ccc75f5bdf387b8041a18bff53bb31b46

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Citations in the corpus

Design of graded lattice structure with optimized mesostructures for additive manufacturing (2018, methodology): “To prevent designed CSs from buckling [34], an additional solid layer is attached to the structural boundary, with a uniform thickness h , as shown in Fig.”
Current and future trends in topology optimization for additive manufacturing (2018, background): “…lattice structure optimization (Wang et al. 2016a; Zhang et al. 2015c; Arabnejad Khanoki and Pasini 2012; Cheng et al. 2017; Liu et al. 2015a; Clausen et al. 2016), i.e., lattice units in prescribed base shape are selected to periodically fill the part interior where an optimal lattice…”
Homogenization-based stiffness optimization and projection of 2D coated structures with orthotropic infill (2019, background): “Compared to their solid counterparts, coated structures with porous infill can obtain significantly increased buckling stability (Clausen et al., 2016), as well as a better performance w.”
Homogenization‐based topology optimization for high‐resolution manufacturable microstructures (2018, methodology): “, porous structures that, apart from weight saving, also may increase buckling stability of topology optimized structures, see Clausen et al.(9,10) In a different approach, Lazarov and Alexandersen use the multiscale finite element method to design high-resolution manufacturable structures.”