Topology Optimization for Reducing Additive Manufacturing Processing Distortions
Weapons and Materials Research Directorate, US Army Research Laboratory Aberdeen Proving Ground United States
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A method is presented for combining topology optimization with an approximate additive manufacturing process model so as to reduce thermal distortions induced during the build process. Thermal distortions are detrimental in any manufacturing process, though in some additive manufacturing processes these distortions may cause a build to completely fail. Here, 2 approximate manufacturing models are used in conjunction with a compliance minimization topology optimization problem. First, a quasi-static thermomechanical model is used that approximates distortions induced by the cooling of the material. Second, an element birth model is used in which elements are activated in turn, and a similar quasi-static thermomechanical problem is used at each step. The overall algorithm uses a compromise objective function to weight the 2 goals thermal displacement minimization and compliance minimization. These models are compared along with a strict overhang constraint method.
- Manufacturing and Industrial Engineering and Control of Production Systems