Topology Report
Topology Report
ABSTRACT
Topology optimization is an optimization method that employs mathematical tools
to optimize material distribution in a part to be designed. Earlier developments of
topology optimization considered conventional manufacturing techniques that have
limitations in producing complex geometries. This has hindered the topology
optimization efforts not to fully be realized. With the emergence of additive
manufacturing (AM) technologies, the technology that builds a part layer upon a layer
directly from three dimensional (3D) model data of the part, however producing complex
shape geometry is no longer an issue. Realization of topology optimization through AM
provides full design freedom for the design engineers.
This report focuses on topologically optimized design approach for additive
manufacturing with a case study on lightweight design of jet engine bracket. The study
result shows that topology optimization is a powerful design technique to reduce the
weight of a product while maintaining the design requirements if additive manufacturing
is considered.
CHAPTER 1
INTRODUCTION
Topology optimization is a mathematical tool to make optimized material
distribution in a part to be designed. By doing so, it gives us a part topology that is more
natural and more complex. There is different topology optimization approaches
developed during the last three decades. For instance, set level approach, homogenization
method, SIMP method and density approach are among the main topology optimization
techniques. The initial topology optimization developments considered the conventional
manufacturing techniques that are either subtractive or formative. These conventional
manufacturing systems have limitations in producing complex shape geometries as they
have different manufacturing constraints. The birth of additive manufacturing gave
another bright future opportunity for topology optimization as with additive
manufacturing (AM) technologies; producing complex shape geometry is achievable.
This is because, in AM, the systems do not require any tooling for producing a part. For
this and other similar capabilities of the technologies, topology optimization and additive
manufacturing are considered ideal couples.
To implement AM technology in production of functional parts, advances in
materials technology and design optimization are considered as the key areas of current
research. Regarding the last mentioned research challenge, a design approach that can
directly transfer the design concept of the engineer to a produced part without any due
consideration for manufacturing constraint and enable optimum utilization of the part
under loading is sought. If proper and efficient algorithms are developed, topology
optimization techniques can play a key role in the future development of AM technology.
The role of topology optimization in AM to design a lightweight product [5].
Most of the topology optimization techniques are carried out by collective use of
Computer Aided Design (CAD) concept, Finite Element Analysis (FEA) concept and
different optimization algorithms in consideration of different manufacturing techniques
as shown on the topology optimization process on Figure 1.1 [4]. The use of CAD in
topology optimization is to make a rough/initial model of the product to be optimized,
whereas FEA is used to see the distribution of stresses and displacements throughout the
product. The topology optimization is performed to remove the areas of the part that are
not sufficiently supporting the applied loads and not undergoing significant deformation
and thus not contributing to the overall performance of the part.
Based on the design problem requirement, different optimization algorithms are
used to remove the portion of the material in the product that are not supporting the
applied load. Moreover, the topology optimization is done to satisfy certain design
objectives and maintain the design constraints. Based on the problem at hand, the
objectives might be to minimize the compliance of the part, i.e. to maximize the stiffness
of the part, as compliance is the inverse of the stiffness; the constraints could be the
maximum allowable deformation, the maximum mass fraction and so on.
Topology optimization generates the optimal shape of a mechanical structure.
Given a predefined domain in the 2D/3D space with boundary conditions and external
loads, the intention is to distribute a percentage of the initial mass on the given domain
such that a global measure takes a minimum. Without any further decisions and guidance
of the user, the method will form the structural shape thus providing a first idea of an
efficient geometry. The design space is discretized by the finite element method to
represent the material distribution and at the same time the structural behavior.
CHAPTER 2
Literature Review
withstand the specified loading conditions (first feedback loop) and (b) the mechanical
integrity and performance of the manufactured component is suitable for conditions in
which it will be employed (second feedback loop). The process flow is discussed in more
detail elsewhere [9].
Figure 2.4: Loading conditions and function description of the engine bracket [11]
commercial software is employed for the topology optimization. The design requirements
for the engine bracket are listed below.
1. The optimized geometry must fit within the original part envelope.
2. The material was Ti-6Al-4V with the assumed yield strength of 904 MPa at the
service temperature (23oC).
3. Minimum material feature size (wall thickness): 1.13 mm.
4. Interface 1: 19 mm diameter pin. The pin was to be considered infinitely stiff for
analysis purposes.
5. Interfaces 2–5: 9.5-24 AS3239-26 machine bolts. Nut faces 10.287 mm max ID
and 14.173 mm min OD. The bolts were to be considered infinitely stiff.
The initial stage of the topology optimization is to divide the part into design (green)
and non-design (yellow) spaces as shown in Figure 2.6. This is to separate the part into
two parts; design space, a space on which the topology optimization is carried out and
non-design space, a space that has nothing to do with the topology optimization and is
unchanged. Furthermore, the non-design space is the part of the object through which, it
is connected to others parts. Both spaces are then meshed using the same tool, Altair
Hypemesh 14 Optistruct commercial software as shown in Figure 2.7. The mesh is done
very fine with element size of 0.25 mm to obtain an even and acceptable materials
distribution throughout the part.
All the loading conditions and the constraints are then applied on the part through
the non-design spaces. The loads are applied separately on the part through the two
horizontal hole surfaces defined as non-design spaces as shown on Figure 2.8 to make the
part ready for optimization. The torque is applied as two equivalent force couples in
different directions as there was a problem in the software to apply a torque.
The topology optimization tool computes the stress and displacement distribution
on the part for all the loads separately. Based on the stress and displacement distribution,
parts that are supporting fewer loads or not significantly contributing to support the load
are removed resulting in a very natural geometry shown in Figure 2.9 (left). As optimized
the geometry is a very natural rough geometry showing the optimized material layout
throughout the part. Since the initial optimized geometry from the tool is rough and does
not look good aesthetically, remodelling of the part is important. The final design is then
prepared on Autodesk Inventor Professional following the topology optimization as
closely as possible as shown in Figure 2.9 (right).
Figure 2.9: Topology optimized geometry: as optimized (left) and re-modelled final part (right) [11]
The newly designed part will have to sustain the same mechanical load while
fulfilling the same design requirements. The final design has to be verified with the given
design criteria that is the yield strength. The von Misses stress values for all the load
cases should not exceed the yield strength. The structural verification analysis is done on
ANSYS R17 Academic Educational tool. As shown in Figure 2.10 the von Misses
stresses for all the cases are below the yield strength of the material.
Figure 2.10: Final engine bracket design stress verification contour plots [11]
The final design satisfies the yielding condition with safety factor from 1.11 to
2.17. The final design is additive manufactured using fused deposition modelling (FDM)
Fortus 450 from Stratasys for the physical design verification as shown in Figure 2.11.
The final design resulted in 65% weight reduction, which is from 2.067 kg original part to
0.72 kg final one.
2.6 Limitations
1. Slow build rates: Many printers lay down material at a speed of one to five
cubic inches per hour. Depending on the part needed, other manufacturing
processes may be significantly faster.
2. High production costs: Sometimes, parts can be made faster using techniques
other than additive manufacturing, so the extra time can lead to higher costs.
Additionally, high-quality additive manufacturing machines can cost anywhere
from $300,000 to $1.5 million, and materials can cost $100 to $150 per pound.
3. Considerable effort in application design and setting process parameters:
Extensive knowledge of material design and the additive manufacturing
machine itself is required to make quality parts.
4. Requires post-processing: The surface finish and dimensional accuracy may
be lower quality than other manufacturing methods.
5. Discontinuous production process: Parts can only be printed one at a time,
preventing economics of scale.
6. Limited component size/small build volume: In most cases, polymer
products are about 1 cubic yard in size, while metal parts may only be one
cubic foot. While larger machines are available, they will come at a cost.
7. Poor mechanical properties: Layering and multiple interfaces can cause
defects in the product.
Conclusion
From the case study, it can be concluded that, topology optimization is a powerful
design concept to reduce the weight of structural products. The reduction of weight saves
huge amount of material and processing energy thus huge amount of money. It also
shows that the capability of topology optimization can be fully utilized with additive
manufacturing techniques, as the manufacturing constraints in the conventional methods
are no longer available. From the case study result, which is 65% weight reduction, it can
also be concluded that topology optimized design for additive manufacturing can reduce
huge portion of the mass thus result in lightweight design.
AM provides a route to physically realize very complex topologies that are
of greater optimality than achievable with traditional manufacturing processes.
Improvements to the efficiency of the topology optimization methods to allow small and
large scale features to coexist without requiring a prohibitive number of design variables
are required. The level set approach appears to offer some potential on this issue where
the design variables are the boundaries rather than the volume. Tools to aid the designer
in handling geometric complexity are also required. It is perhaps unrealistic to expect a
panacea of automatic tools to feature recognize and convert complex topology
meshes into a mathematical CAD form, but this would be very useful. Until there are
further developments in this area, remaining in the mesh form for geometric post-
processing appears to be the only realistic way of retaining the level of complexity in the
design.
References