Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization
Topology optimization offers a possibility to derive load-compliant structures. These structures tend to be complex, and conventional manufacturing offers only limited possibilities for their production. Additive manufacturing provides a remedy due to its high design freedom. However, this type of m...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-03-01
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| Series: | Algorithms |
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| Online Access: | https://www.mdpi.com/1999-4893/15/3/99 |
| _version_ | 1797473293632012288 |
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| author | Jan Holoch Sven Lenhardt Sven Revfi Albert Albers |
| author_facet | Jan Holoch Sven Lenhardt Sven Revfi Albert Albers |
| author_sort | Jan Holoch |
| collection | DOAJ |
| description | Topology optimization offers a possibility to derive load-compliant structures. These structures tend to be complex, and conventional manufacturing offers only limited possibilities for their production. Additive manufacturing provides a remedy due to its high design freedom. However, this type of manufacturing can cause areas of different material properties in the final part. For example, in selective laser melting, three areas of different porosity can occur depending on the process parameters, the geometry of the part and the print direction, resulting in a direct interrelation between manufacturing and design. In order to address this interrelation in design finding, this contribution presents an optimization method in which the three porous areas are identified and the associated material properties are considered iteratively in a topology optimization. For this purpose, the topology optimization is interrupted in each iteration. Afterwards, the three areas as well as the material properties are determined and transferred back to the topology optimization, whereby those properties are used for the calculation of the next iteration. By using the optimization method, a design with increased volume-specific stiffness compared to a design of a standard topology optimization can be created and will be used in the future as a basis for the extension by a global strength constraint to maintain the maximum permissible stress and the minimum wall thickness. |
| first_indexed | 2024-03-09T20:12:42Z |
| format | Article |
| id | doaj.art-856baa9760934a9ca3d5040b0a74464b |
| institution | Directory Open Access Journal |
| issn | 1999-4893 |
| language | English |
| last_indexed | 2024-03-09T20:12:42Z |
| publishDate | 2022-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Algorithms |
| spelling | doaj.art-856baa9760934a9ca3d5040b0a74464b2023-11-24T00:09:06ZengMDPI AGAlgorithms1999-48932022-03-011539910.3390/a15030099Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology OptimizationJan Holoch0Sven Lenhardt1Sven Revfi2Albert Albers3IPEK—Institute of Product Engineering at Karlsruhe Institute of Technology (KIT), Kaiserstrasse 10, 76131 Karlsruhe, GermanyIPEK—Institute of Product Engineering at Karlsruhe Institute of Technology (KIT), Kaiserstrasse 10, 76131 Karlsruhe, GermanyIPEK—Institute of Product Engineering at Karlsruhe Institute of Technology (KIT), Kaiserstrasse 10, 76131 Karlsruhe, GermanyIPEK—Institute of Product Engineering at Karlsruhe Institute of Technology (KIT), Kaiserstrasse 10, 76131 Karlsruhe, GermanyTopology optimization offers a possibility to derive load-compliant structures. These structures tend to be complex, and conventional manufacturing offers only limited possibilities for their production. Additive manufacturing provides a remedy due to its high design freedom. However, this type of manufacturing can cause areas of different material properties in the final part. For example, in selective laser melting, three areas of different porosity can occur depending on the process parameters, the geometry of the part and the print direction, resulting in a direct interrelation between manufacturing and design. In order to address this interrelation in design finding, this contribution presents an optimization method in which the three porous areas are identified and the associated material properties are considered iteratively in a topology optimization. For this purpose, the topology optimization is interrupted in each iteration. Afterwards, the three areas as well as the material properties are determined and transferred back to the topology optimization, whereby those properties are used for the calculation of the next iteration. By using the optimization method, a design with increased volume-specific stiffness compared to a design of a standard topology optimization can be created and will be used in the future as a basis for the extension by a global strength constraint to maintain the maximum permissible stress and the minimum wall thickness.https://www.mdpi.com/1999-4893/15/3/99additive manufacturingselective laser meltingfinite element analysistopology optimizationproduct developmentdesign finding |
| spellingShingle | Jan Holoch Sven Lenhardt Sven Revfi Albert Albers Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization Algorithms additive manufacturing selective laser melting finite element analysis topology optimization product development design finding |
| title | Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization |
| title_full | Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization |
| title_fullStr | Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization |
| title_full_unstemmed | Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization |
| title_short | Design of Selective Laser Melting (SLM) Structures: Consideration of Different Material Properties in Multiple Surface Layers Resulting from the Manufacturing in a Topology Optimization |
| title_sort | design of selective laser melting slm structures consideration of different material properties in multiple surface layers resulting from the manufacturing in a topology optimization |
| topic | additive manufacturing selective laser melting finite element analysis topology optimization product development design finding |
| url | https://www.mdpi.com/1999-4893/15/3/99 |
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