Structural Multiscale Topology Optimization With Stress Constraint For Additive Manufacturing

In this paper a phase-field approach for structural topology optimization for a 3D-printing process which includes stress constraint and potentially multiple materials or multiscales is analyzed. First order necessary optimality conditions are rigorously derived and a numerical algorithm which implements the method is presented. A sensitivity study with respect to some parameters is conducted for a two-dimensional cantilever beam problem. Finally, a possible workflow to obtain a 3D-printed object from the numerical solutions is described and the final structure is printed using a fused deposition modeling (FDM) 3D printer.

METAL ADDITIVE MANUFACTURING A comprehensive review of additive manufacturing processes for metallic structures Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise. Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource: Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.

Evolutionary Structural Optimization (ESO) is a design method based on the simple concept of gradually removing inefficient material from a structure as it is being designed. Through this method, the resulting structure will evolve towards its optimum shape. The latest techniques and results of ESO are presented here, illustrated by numerous clear and detailed examples. Sections cover the fundamental aspects of the method, the application to multiple load cases and multiple support environments, frequency optimization, stiffness and displacement constraints, buckling, jointed frame structures, shape optimization, and stress reduction. This is followed by a section describing Evolve97, a software package which will allow readers to try the ideas of ESO themselves and to solve their optimization problems. This software is provided on a computer diskette which accompanies the book.

To analyze the impact of different objective functions and additive manufacturing (AM) constraints on structural topology optimization, it is necessary to perform an in-depth comparative study. This analysis should consider specific structural design factors, such as compliance, volume, or stress minimization, and assess their effects on the topology optimization for AM. In addition, the inclusion of AM constraints can have a significant influence on various aspects, including optimal part geometry, part volume, support structure volume, and structural performance. Thus, it is essential to examine and compare these factors to determine the optimal part design for AM. This study focuses on comparing topology optimization results obtained using compliance, stress, or multi-objective minimization, with and without AM constraints. The comparative analysis is conducted in the study, utilizing four structural design examples: cantilever beam, bridge-shaped structure, L-shaped beam and connecting rod. The comparison results provide insights into the effects of build orientation, AM constraints such as overhang, and different design objectives on the structural topology optimization for AM.

Multiscale Structural Topology Optimization discusses the development of a multiscale design framework for topology optimization of multiscale nonlinear structures. With the intention to alleviate the heavy computational burden of the design framework, the authors present a POD-based adaptive surrogate model for the RVE solutions at the microscopic scale and make a step further towards the design of multiscale elastoviscoplastic structures. Various optimization methods for structural size, shape, and topology designs have been developed and widely employed in engineering applications. Topology optimization has been recognized as one of the most effective tools for least weight and performance design, especially in aeronautics and aerospace engineering. This book focuses on the simultaneous design of both macroscopic structure and microscopic materials. In this model, the material microstructures are optimized in response to the macroscopic solution, which results in the nonlinearity of the equilibrium problem of the interface of the two scales. The authors include a reduce database model from a set of numerical experiments in the space of effective strain. Presents the first attempts towards topology optimization design of nonlinear highly heterogeneous structures Helps with simultaneous design of the topologies of both macroscopic structure and microscopic materials Helps with development of computer codes for the designs of nonlinear structures and of materials with extreme constitutive properties Focuses on the simultaneous design of both macroscopic structure and microscopic materials Includes a reduce database model from a set of numerical experiments in the space of effective strain

The volume includes papers from the WSCMO conference in Braunschweig 2017 presenting research of all aspects of the optimal design of structures as well as multidisciplinary design optimization where the involved disciplines deal with the analysis of solids, fluids or other field problems. Also presented are practical applications of optimization methods and the corresponding software development in all branches of technology.

This book presents recent research on sustainable building materials and their various applications. Topics include such items as fiber reinforced concrete, the use of mineral admixtures. self-sensing cement composites, the use of nanomaterials for structural health monitoring and the production of geopolymer mortar. Keywords: Light Transmitting Concrete, Self-Compacting Concrete, Light-Weight Concrete, Polymer Concrete, Porous Concrete, Eco-Friendly Building Material, Cement Composite, Geopolymer Composites, Sustainable Bricks, Cement, Sisal Fiber, Glass Fiber, Nanomaterials, Metakaoline, Fly Ash, Silica Fume, Rice Husk Ash, Oyster Shells, Bitumen, Sugarcane Bagasse Ash, Herbocrete, Waste Foundry Sand, Swell Pressure of Clay, Quarry Dust, Sensors, Topology Optimization, Soil Stabilization.

The book presents a set of novel, efficient and systematic concurrent multiscale optimization methods by considering the distribution of the material in macro-scale and the unit-cell configuration design in micro-scale simultaneously. Different from the traditional optimization method that is performed in a single scale, the proposed methods could generate a great deal of improvements in structural performance through the multiscale structure-material concurrent optimum design.The proposed theory and methods are related to statics, dynamics, thermoelastics and the coupling of different physical fields. Therefore, it provides a comprehensive designing scheme when multiple factors are taken into account. For example, the designing scheme can have a great significance on enhancing the structural performances under coupled multi-physical fields, such as load bearing capacity, vibration resistance ability, and safety under thermal stress and so on.Several numerical examples are highlighted in this unique volume based on practical engineering applications. The examples collectively demonstrate drastically improved designs featuring excellent unit-cell configuration and highly regular macroscale material distribution in a variety of industrial applications.