Topology optimization of additively manufactured fluidic components free of internal support structures

Behrou, Reza; Kirsch, Kathryn; Ranjan, Ram; Guest, James K.

doi:10.1016/j.cma.2021.114270

Topology optimization of additively manufactured fluidic components free of internal support structures

Journal Article · Sun Nov 28 23:00:00 EST 2021 · Computer Methods in Applied Mechanics and Engineering

DOI:https://doi.org/10.1016/j.cma.2021.114270· OSTI ID:1976971

^[1]; ^[2]; Ranjan, Ram ^[2]; Guest, James K. ^[3]

RunToSolve, LLC., Towson, MD (United States); OSTI
Raytheon Technologies Research Center, East Hartford, CT (United States)
RunToSolve, LLC., Towson, MD (United States); Johns Hopkins University, Baltimore, MD (United States)

This report integrates projection-based approaches for implementing overhang constraints with fluid topology optimization to design additively manufactured fluidic components that do not require internal support structures. Internal support structures are challenging, potentially impossible to remove in complex fluid networks, yet would degrade fluidic performance if left within the part. This presents a major challenge in coupling topology optimization with additive manufacturing in the design of fluid components. The proposed approach leverages past work in overhang constraints for solid mechanics, including projection formulations and adjoint sensitivity analysis, and considers incompressible Navier–Stokes equations for laminar fluid flow. The approach is demonstrated on 2D and 3D fluid topology optimization problems to minimize pressure drop and constrain mass flow rates in pipes and manifolds. Resulting designs are crisp, logical, satisfy performance constraints, and satisfy overhang constraints, eliminating the need for internal support structures.

View Accepted Manuscript (DOE)

Research Organization:: Raytheon Technologies Corporation, Waltham, MA (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E)

Grant/Contract Number:: AR0001121

OSTI ID:: 1976971

Alternate ID(s):: OSTI ID: 1840620

Journal Information:: Computer Methods in Applied Mechanics and Engineering, Journal Name: Computer Methods in Applied Mechanics and Engineering Journal Issue: C Vol. 389; ISSN 0045-7825

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
97 MATHEMATICS AND COMPUTING
additive manufacturing
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incompressible flow
overhang constraints
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Topology optimization of additively manufactured fluidic components free of internal support structures

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