TY - JOUR
T1 - Topology Optimization for additive manufacturing with distortion constraints
AU - Misiun, Grzegorz
AU - van de Ven, Emiel
AU - Langelaar, Matthijs
AU - Geijselaers, Hubert
AU - van Keulen, Fred
AU - van den Boogaard, Ton
AU - Ayas, Can
PY - 2021
Y1 - 2021
N2 - An important cause of failure in powder bed additive manufacturing is the distortion of the part due to thermal shrinkage during printing and the relaxation of residual stresses after its release from the base plate. In this paper, Additive Manufacturing simulations are coupled with Topology Optimization in order to generate designs that are not susceptible to failure associated with distortion. Two possible causes of failure are accounted for: recoater collision and global distortion of the product. Both are considered by simulation of the build process and defined as constraints in the context of a Solid Isotropic Material with Penalization method based topological optimization. The adjoint method is used to derive the sensitivities of the additive manufacturing constraints. The method is demonstrated with the 2D and 3D optimization of a bracket. Next to global topological changes, the obtained designs show features that are aimed at facilitating the printing process. These features resemble supports that are routinely applied to powder bed additive manufacturing. The formulated constraints were found to prevent excessive part distortion and associated build failures in all cases, against a modest increase in the compliance of the bracket.
AB - An important cause of failure in powder bed additive manufacturing is the distortion of the part due to thermal shrinkage during printing and the relaxation of residual stresses after its release from the base plate. In this paper, Additive Manufacturing simulations are coupled with Topology Optimization in order to generate designs that are not susceptible to failure associated with distortion. Two possible causes of failure are accounted for: recoater collision and global distortion of the product. Both are considered by simulation of the build process and defined as constraints in the context of a Solid Isotropic Material with Penalization method based topological optimization. The adjoint method is used to derive the sensitivities of the additive manufacturing constraints. The method is demonstrated with the 2D and 3D optimization of a bracket. Next to global topological changes, the obtained designs show features that are aimed at facilitating the printing process. These features resemble supports that are routinely applied to powder bed additive manufacturing. The formulated constraints were found to prevent excessive part distortion and associated build failures in all cases, against a modest increase in the compliance of the bracket.
KW - Additive manufacturing
KW - Inherent strains
KW - Recoater collision
KW - Shape distortions
KW - Topology Optimization
UR - http://www.scopus.com/inward/record.url?scp=85113409530&partnerID=8YFLogxK
U2 - 10.1016/j.cma.2021.114095
DO - 10.1016/j.cma.2021.114095
M3 - Article
AN - SCOPUS:85113409530
SN - 0045-7825
VL - 386
JO - Computer Methods in Applied Mechanics and Engineering
JF - Computer Methods in Applied Mechanics and Engineering
M1 - 114095
ER -