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A thermal model for topology optimization in additive manufacturing: Design of support structures and geometry orientation
Univ Estadual Campinas UNICAMP, Brazil.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, Faculty of Science & Engineering.
Univ Sao Paulo, Brazil.
Arcam EBM Ctr Excellence, Sweden.
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2024 (English)In: Computers & structures, ISSN 0045-7949, E-ISSN 1879-2243, Vol. 301, article id 107453Article in journal (Refereed) Published
Abstract [en]

In this study, we present an efficient Topology Optimization (TO) approach designed to optimize support structures in metal Additive Manufacturing (AM), with a particular focus on Powder Bed Fusion (PBF) technology. The developed framework uses a purely thermal formulation to identify regions within the design that are susceptible to high heat concentrations. In the proposed modeling of the AM process, we postulate that new material layers are included in a partially built design that has already cooled to a controlled temperature. This aspect provides a layer -by -layer model of AM entirely local, enabling the building process parallelization and resulting in an algorithm with superior computational efficiency. Numerical results show the robustness of the proposed strategy, with the successful incorporation of support structures beneath overhanging surfaces and their effectiveness across a wide range of geometries and orientations. Furthermore, this framework is also applied to optimize the geometry orientation within the build chamber, further enhancing its applicability in the AM context.

Place, publisher, year, edition, pages
PERGAMON-ELSEVIER SCIENCE LTD , 2024. Vol. 301, article id 107453
Keywords [en]
Topology optimization; Additive manufacturing; Layer-by-layer process; Thermal conductivity; Optimal support structures; Geometry orientation
National Category
Computer Sciences
Identifiers
URN: urn:nbn:se:liu:diva-206665DOI: 10.1016/j.compstruc.2024.107453ISI: 001257917700001OAI: oai:DiVA.org:liu-206665DiVA, id: diva2:1891518
Note

Funding Agencies|So Paulo Research Foundation (FAPESP) [2020/14288- 0, 2023/00822-2, 2013/07375-0]; National Council for Scientific and Technological Development-CNPq [304192/2019-8, 304074/2020-9, 308704/2022-3, 307679/2023-3]

Available from: 2024-08-22 Created: 2024-08-22 Last updated: 2024-08-22

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