Concurrent Optimization of Print Orientation, Stacking Sequence, and Topology for Fiber Reinforced Additively Manufactured Components
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Authors
Ray, T Noah
Date
2025-01-09
Type
thesis
Language
eng
Keyword
Topology , Composite , Fiber , Orientation , Optimization , Additive Manufacturing , Numerical Optimization , Finite Element
Alternative Title
Abstract
Fiber reinforced additive manufacturing (FRAM) combines the benefits of composite materials and additive manufacturing to create components which are made of high-performance materials, have complex geometry, and are highly configurable to address a design objective. As such, FRAM components are perfect candidates for numerical optimization methods including fiber orientation optimization and topology optimization. Many existing methods already optimize fiber reinforcement orientation, however, constrain fiber reinforcement to exist within a user-defined FRAM print-plane(s). This style of problem formulation fundamentally limits the orientation design freedom, resulting in a smaller envelope of attainable anisotropic material properties and a negative influence on subsequent topology optimization. Overall, this limits the effectiveness and optimality of designs which are currently produced for FRAM.
This thesis presents novel numerical optimization methodologies for FRAM which redefine the optimization problem statement, propose new numerical methods, address shortcomings of existing methodologies, and are used to solve complex design problems. The proposed methodology, presented as “Theta”, is a holistic optimization platform which performs concurrent print orientation optimization (POO), stacking sequence optimization (SSO), and topology optimization (TO). Print orientation (PO) design variables, , and stacking sequence (SS) design variables, , are used to establish a domain-level, 3D orientation of FRAM print-plane and configuration of in-plane fiber reinforcements. The PO and SS represent a diverse configuration of anisotropic material properties which are optimized based on a structural objective function and the loading / geometry of a particular component. Density-based TO design variables, , are used to simultaneously optimize the material distribution of the component, within the anisotropic state, and contribute to minimization of the common objective function. The proposed methodology culminates in the solution of four case-studies which are representative of complex, real-world engineering design problems. The proposed methodology reduces structural compliance of the rear legs of an aircraft seat by 38%, the mass of a 3D bracket by 51%, the structural compliance of a 3D bracket by 38%, and the structural compliance of an eATV rear assembly by 92% compared to the metallic baseline designs. The methodology is used to determine unique, unintuitive anisotropic material property configurations and optimized material distributions for all case studies which improve a defined structural performance metric. Furthermore, solutions to the case studies are compared to baseline metallic components and conventional implementations of FRAM to further demonstrate the benefits and effectiveness of the proposed methodology.
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Queen's University's Thesis/Dissertation Non-Exclusive License for Deposit to QSpace and Library and Archives Canada
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This publication is made available by the authority of the copyright owner solely for the purpose of private study and research and may not be copied or reproduced except as permitted by the copyright laws without written authority from the copyright owner.
ProQuest PhD and Master's Theses International Dissemination Agreement
Intellectual Property Guidelines at Queen's University
Copying and Preserving Your Thesis
This publication is made available by the authority of the copyright owner solely for the purpose of private study and research and may not be copied or reproduced except as permitted by the copyright laws without written authority from the copyright owner.