Manufacturing Constraints for Topology Optimization: A Particle Diffusion Based Methodology
With the need for improved performance becoming more apparent in the engineering workplace, numerical tools like design optimization and topology optimization have been turned to in order to generate new unconventional design concepts. Leveraging concepts from traditional design optimization, topology optimization is a generalized tool suitable for many different applications. However, a challenge posed by topology optimization has been the determination of feasible results from a manufacturing perspective. Manufacturing constraints for topology optimization have been developed over the years in order to guide the optimization problem to a result that is feasible for manufacturing. Many methods have been proposed and have shown that topology optimization results can be developed with specific manufacturing considerations in mind. This work presents a new manufacturing constraint methodology for topology optimization which utilizes a particle diffusion method to mathematically model and eliminate non-desirable geometric features in the topology optimization procedure. Here, the geometric feature modeling and elimination vary based on the given manufacturing process. The chosen manufacturing constraints studied in this work are single plane casting, split plane casting, 3-axis milling, 5-axis milling, and turning. The particle diffusion problem leverages the finite element discretization of the topology optimization problem for setup but does not require a finite element solution to the problem. Through the mathematical relationship developed with particle diffusion times and not requiring a finite element solution, particle diffusion for manufacturing constraints overcomes some of the shortcomings of other methods in the existing literature. The entire methodology is formulated in a differentiable manner where design sensitivity calculations can be taken and used in a gradient based optimization scheme. In five numerical examples these manufacturing constraints utilizing particle diffusion are shown. For all examples, manufacturing feasibility for the chosen manufacturing process was achieved at the cost of increased structural compliance.
URI for this recordhttp://hdl.handle.net/1974/27482
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