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Design and experimental validation of self-supporting topologies for additive manufacturing
journal contribution
posted on 2019-01-01, 00:00 authored by Yun-Fei (Jack) Fu, Bernard RolfeBernard Rolfe, Louis Chiu, Yanan WangYanan Wang, X Huang, Kazem GhabraieKazem GhabraieIncorporating additive manufacturing (AM) constraints in topology optimisation can lead to performance optimality while ensuring manufacturability of designs. Numerical techniques have been previously proposed to obtain support-free designs in AM, however, few works have verified the manufacturability of their solutions. Physical verification of manufacturability becomes more critical recalling that the conventional density-based topology optimisation methods will inevitably require post-processing to smooth the boundaries before sending the results to a 3D printer. This paper presents the smooth design of self-supporting topologies using the combination of a new Solid Isotropic Microstructure with Penalisation method (SIMP) developed based on elemental volume fractions and an existing AM filter. Manufacturability of selected simulation results are verified with Fused Deposition Modeling (FDM) technology. It is illustrated that the proposed method is able to generate convergent self-supporting topologies which are printable using FDM.
History
Journal
Virtual and physical prototypingVolume
14Issue
4Pagination
382 - 394Publisher
Taylor & FrancisLocation
Abingdon, Eng.Publisher DOI
ISSN
1745-2759eISSN
1745-2767Language
engPublication classification
C Journal article; C1 Refereed article in a scholarly journalCopyright notice
2019, Informa UK Limited, trading as Taylor & Francis GroupUsage metrics
Keywords
Topology optimisationelemental volume fractionslevel-set functionsmooth boundary representationadditive manufacturingselfsupporting designScience & TechnologyTechnologyEngineering, ManufacturingMaterials Science, MultidisciplinaryEngineeringMaterials Scienceself-supporting designCONTINUUM STRUCTURESOVERHANG CONSTRAINTSTRUCTURAL OPTIMIZATIONLENGTH SCALEFILTERSSHAPEMechanical Engineering
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