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Title: Multi-solution nature of topology optimization and its application in design for additive manufacturing

Abstract

The purpose of this paper is to introduce the multi-solution nature of topology optimization (TO) as a design tool for additive manufacturing (AM). The sensitivity of topologically optimized parts and manufacturing constraints to the initial starting point of the optimization process leading to structures with equivalent performance is explored. A modified bi-directional evolutionary structural optimization (BESO) code was used as the numerical approach to optimize a cantilever beam problem and reduce the mass by 50 per cent. Several optimized structures with relatively equivalent mechanical performance were generated by changing the initial starting point of the TO algorithm. These optimized structures were manufactured using fused deposition modeling (FDM). The equivalence of strain distribution in FDM parts was tested with the digital image correlation (DIC) technique and compared with that from the modified BESO code.The results confirm that TO could lead to a wide variety of non-unique solutions based on loading and manufacturability constraints. The modified BESO code was able to reduce the support structure needed to build the simple two-dimensional cantilever beam by 15 per cent while keeping the mechanical performance at the same level. Finally, the originality of this paper lies in introduction and application of the multi-solution nature ofmore » TO for AM as a design tool for optimizing structures with minimized features in the overhang condition and the need for support structures.« less

Authors:
 [1];  [2]; ORCiD logo [3];  [3]
+ Show Author Affiliations
  1. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Univ. of Tennessee, Knoxville, TN (United States)
  3. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1607308
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Rapid Prototyping Journal
Additional Journal Information:
Journal Volume: 25; Journal Issue: 9; Journal ID: ISSN 1355-2546
Publisher:
Emerald Group Publishing
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; fused deposition modeling; finite element analysis; additive manufacturing; topology optimization; overhang; support structure

Citation Formats

Rezayat, Hassan, Bell, Jared, Plotkowski, Alex, and Babu, Sudarsanam. Multi-solution nature of topology optimization and its application in design for additive manufacturing. United States: N. p., 2019. Web. doi:10.1108/RPJ-01-2018-0009.
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Rezayat, Hassan, Bell, Jared, Plotkowski, Alex, & Babu, Sudarsanam. Multi-solution nature of topology optimization and its application in design for additive manufacturing. United States. https://doi.org/10.1108/RPJ-01-2018-0009
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Rezayat, Hassan, Bell, Jared, Plotkowski, Alex, and Babu, Sudarsanam. Mon . "Multi-solution nature of topology optimization and its application in design for additive manufacturing". United States. https://doi.org/10.1108/RPJ-01-2018-0009. https://www.osti.gov/servlets/purl/1607308.
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@article{osti_1607308,
title = {Multi-solution nature of topology optimization and its application in design for additive manufacturing},
author = {Rezayat, Hassan and Bell, Jared and Plotkowski, Alex and Babu, Sudarsanam},
abstractNote = {The purpose of this paper is to introduce the multi-solution nature of topology optimization (TO) as a design tool for additive manufacturing (AM). The sensitivity of topologically optimized parts and manufacturing constraints to the initial starting point of the optimization process leading to structures with equivalent performance is explored. A modified bi-directional evolutionary structural optimization (BESO) code was used as the numerical approach to optimize a cantilever beam problem and reduce the mass by 50 per cent. Several optimized structures with relatively equivalent mechanical performance were generated by changing the initial starting point of the TO algorithm. These optimized structures were manufactured using fused deposition modeling (FDM). The equivalence of strain distribution in FDM parts was tested with the digital image correlation (DIC) technique and compared with that from the modified BESO code.The results confirm that TO could lead to a wide variety of non-unique solutions based on loading and manufacturability constraints. The modified BESO code was able to reduce the support structure needed to build the simple two-dimensional cantilever beam by 15 per cent while keeping the mechanical performance at the same level. Finally, the originality of this paper lies in introduction and application of the multi-solution nature of TO for AM as a design tool for optimizing structures with minimized features in the overhang condition and the need for support structures.},
doi = {10.1108/RPJ-01-2018-0009},
journal = {Rapid Prototyping Journal},
number = 9,
volume = 25,
place = {United States},
year = {2019},
month = {10}
}
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Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1108/RPJ-01-2018-0009
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Cited by: 1 work
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Figures / Tables:

Figure 1 Figure 1: Definition of 45-degree local overhang condition in additive manufacturing (left). The overhang criteria used to detect the elements in overhang condition (right). Only one of the bottom neighboring elements must be filled for the angle to be greater than or equal to 45 degrees and thus not inmore » overhang condition.« less
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Works referenced in this record:

Optimal shape design as a material distribution problem
journal, December 1989

A New Algorithm for Bi-Directional Evolutionary Structural Optimization
journal, January 2006

  • Huang, Xiaodong; Xie, Yi Min; Burry, Mark Cameron
  • JSME International Journal Series C, Vol. 49, Issue 4
  • DOI: 10.1299/jsmec.49.1091

Generating optimal topologies in structural design using a homogenization method
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  • Bendsøe, Martin Philip; Kikuchi, Noboru
  • Computer Methods in Applied Mechanics and Engineering, Vol. 71, Issue 2
  • DOI: 10.1016/0045-7825(88)90086-2

Support structure design in additive manufacturing based on topology optimization
journal, July 2017

  • Kuo, Yu-Hsin; Cheng, Chih-Chun; Lin, Yang-Shan
  • Structural and Multidisciplinary Optimization, Vol. 57, Issue 1
  • DOI: 10.1007/s00158-017-1743-z

Support structure constrained topology optimization for additive manufacturing
journal, December 2016

Additive manufacturing
journal, November 2014

Evolutionary structural optimization for problems with stiffness constraints
journal, April 1996

Structure–mechanical property relationship in fused deposition modelling
journal, November 2014

A 99 line topology optimization code written in Matlab
journal, April 2001

Additive Manufacturing
journal, January 2016

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    Figures / Tables found in this record:

    Figure 1 (p. 11)figure
    Figure 2 (p. 11)figure
    Figure 3 (p. 12)figure
    Figure 4 (p. 12)figure
    Figure 5 (p. 13)figure
    Figure 6 (p. 14)figure
    Figure 7 (p. 15)figure
    Figure 8 (p. 15)figure
    Figure 9 (p. 16)figure
    Figure 10 (p. 17)figure
    Figure 11 (p. 18)figure
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