Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation. Issue 4 (20th June 2017)

• Record Type: Journal Article
• Authors: Cheng, Lin; Zhang, Pu; Biyikli, Emre; Bai, Jiaxi; Robbins, Joshua; To, Albert
• Is Part Of: Rapid prototyping journal. Volume 23:Issue 4(2017)
• Page Start: 660
• Page End: 677
• Publication Date: 2017-06-20
• Subjects: Additive manufacturing -- Reconstruction -- Homogenization -- Topology optimization -- Cellular structure; Engineering design -- Periodicals; 620.004205
• DOI: 10.1108/RPJ-04-2016-0069
• Languages: English
• ISSNs: 1355-2546

Abstract

Abstract : Purpose: The purpose of the paper is to propose a homogenization-based topology optimization method to optimize the design of variable-density cellular structure, in order to achieve lightweight design and overcome some of the manufacturability issues in additive manufacturing. Design/methodology/approach: First, homogenization is performed to capture the effective mechanical properties of cellular structures through the scaling law as a function their relative density. Second, the scaling law is used directly in the topology optimization algorithm to compute the optimal density distribution for the part being optimized. Third, a new technique is presented to reconstruct the computer-aided design (CAD) model of the optimal variable-density cellular structure. The proposed method is validated by comparing the results obtained through homogenized model, full-scale simulation and experimentally testing the optimized parts after being additive manufactured. Findings: The test examples demonstrate that the homogenization-based method is efficient, accurate and is able to produce manufacturable designs. Originality/value: The optimized designs in our examples also show significant increase in stiffness and strength when compared to the original designs with identical overall weight.