Topology optimization with additive manufacturing size constraints
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Authors
Morin, Rosalie
Date
Type
thesis
Language
eng
Keyword
Topology optimization , Moving morphable components , Additive manufacturing , Build volume constraint
Alternative Title
Abstract
Structures re-designed with topology optimization (TO) for additive manufacturing (AM) are restrained to the maximum build volume of the machine. Existing work addressing this limitation is the multi-component topology optimization for additive manufacturing (MTO-A) framework that uses an element-wise design variable (DV) method to simultaneously optimize the material layout and design of components to fit inside an AM machine. The scalability and practicality of this approach is limited in that the computational cost is directly related to the number of elements in each design field and joints required for re-assembly are not accounted for.
This work proposes a novel mathematical method that sequentially solves two subproblems to obtain the optimal material layout of a structure and the optimal decomposition points of a multi-component design satisfying the AM size constraints. Presented as decomposition optimization, the latter subproblem adopts the moving morphable components (MMC) framework to introduce AM size constraints to the optimization scheme with few design variables to enhance scalability of the problem. Joints are integrated by an MMC, referred to as partitioning rectangles, to obtain their optimal distribution in the design with the goal of minimizing the compliance for a completely decomposed structure. The AM size constraint is directly introduced in the geometry description of the MMC so that the components that fall within a partitioning rectangle are not bigger than the size of the AM machine. Additionally, an incomplete decomposition fraction constraint is introduced to limit the amount of structural material that exists outside of a partitioning rectangle. The proposed methodology is tested on three numerical examples to demonstrate its capabilities and limitations.
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Copying and Preserving Your Thesis
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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.