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Topology optimization of an object for additive manufacturing

Ntintakis Ioannis

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Summary

Engineers focus on the design of new added-value products, which satisfy the human needs. The product-design process follows a base line. It starts from an idea and through 2D and 3D design, models are created for creating prototypes, which are then evaluated. During this process many design parameters and other specifications have to be taken into account. Topology optimization is a well-known design decision tool for designers/engineers. Generative design based on topology optimization and artificial-intelligent algorithms is also a helpful design tool, especially in the early design stage of conceptual design. Topology optimization and generative design outcomes are characterized by a complex-structure shape. Often these structures are difficult, or impossible to be produced with traditional fabrication techniques. Additive manufacturing, due to its ability to fabricate any complex shape, is the appropriate method to overcome this limitation. In this thesis topology optimization and generative design are utilized for the design of a consumer product and also for the redesign of mechanical components, taking into account the limitations of the selected additive manufacturing technique. The developments of additive manufacturing in recent years and its close relevance with the results of TO and GD process are very encouraging. Auxetic materials have enhanced dynamical properties and damping behavior, and thus they can be used in certain applications. This property is usually explained from the microstructure, although other models have been used as well, such as chiral, or mechanism-based models. Auxetic materials are used in several fields, however, optimal design towards dynamical properties is still under investigation. In this study the efficiency of auxetic materials on a dynamic loading caused by bullet penetration has been compared with non-auxetic materials. A key factor of additive manufacturing for the fabrication of light weight structures is the selected infill structures. In the current thesis by utilizing topology optimization, new infill structures are designed with the use of the SIMP topology optimization method. The selected method predicts the material distribution in a specific and predefined domain in an accurate way, but it does not check other material properties, such us structure isotropy. In the current thesis a hybrid approach has been adopted, which combines topology optimization and the classic homogenization method to evaluate the topological optimized microstructures. Using an RVE (Representative Volume Element) the results are evaluated numerically. Then, using additive manufacturing, specimens of both microstructures are fabricated and evaluated with compression and tensile strength tests. The results agree with the numerical findings that the microstructures have anisotropic behavior.

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