MSc. Thesis presentation Topology-optimization-based model ...€¦ · MSc. Thesis presentation...
Transcript of MSc. Thesis presentation Topology-optimization-based model ...€¦ · MSc. Thesis presentation...
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The information in this presentation is proprietary and confidential and shall not be disclosed to or
used by a third party unless specif ically authorised by the relevant GKN plc group company.
MSc. Thesis presentation
Topology-optimization-based model definition with manufacturing constraints
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Mariniello Emanuele I 12/06/2019
Supervisors Co-supervisor
Prof. Alberto Boschetto Ing. Timi Ojo Rus
Prof.ssa Luana Bottini
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Aim
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Presentation outline
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1. Introduction
- Additive Manufacturing
- Topology Optimization
2. Topology Optimization
- Methodology
- Outputs
3. Post Processing
- Methodology
- Outputs
- Comparison
4. Conclusions and Further works
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Additive Manufacturing
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The Additive Manufacturing processes are classified into 7 categories:
a) VAT Photopolymerization
b) Material Jetting
c) Binder Jetting
d) Material Extrusion
e) Powder Bed Fusion
f) Sheet Lamination
g) Directed Energy Deposition
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Topology Optimization
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It is a mathematical method that optimizes material with the typical goal of reduce the
mass of an object without compromise the mechanical resistance of its structure.
Solid Isotropic Material with Penalization (SIMP)
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Topology Optimization Software
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➢ Hyperworks
➢ Ansys
➢ Siemens NX
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Topology Optimization - Procedure
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1. Enough space to insert the pin in the lug;
2. Each interfaces between two consecutive sectors
needs to be flat;
3. Original flanges to maintain the seal condition and
design guidelines;
4. No application of “Air Force Method” normative.
Design Space constraints:
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Design Space and No Design Space
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Mechanical Loads
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Mechanical Loads
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Dummy
TRS
Load
Constraints
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Topology Optimization parameters
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Mindim: 7,5
Maxdim: 15
Stress Constraint: < 800 MPa
Volume fraction: 0,05
Objective function: minimize compliance
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0,505
TO Hyperworks Output
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Post Processing constraints
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1. The output of the TO has rough surface, it must be smoothed;
2. The connection between BHS and TRS must be closed;
3. Geometry on the bottom that allows to perform the liquid penetrate
inspection;
4. To reduce excessive use of support material, the structure needs to
have an overhang angle lower than 45 degrees, where it is possible.
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Post Processing “Concept 1” (No overhang angle constraints)
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Weight Reduction:
31 %
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Post Processing “Concept 2” (with overhang angle constraints)
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Post Processing “Concept 2” (with overhang angle constraints)
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Weight Reduction:
28 %
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“Concept 1” vs “Concept 2”
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Concept 1 Concept 2
OTM
Displacement AnalysisOriginal
≈ 4 mm
≈ 3,8 mm
≈ 6 mm
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“Concept 1” vs “Concept 2”
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FBO Tension
Stress Analysis
Concept 1
Concept 2
Max ≈ 1000 MPa
Max ≈ 780 MPa
Max ≈ 750 MPa
Original
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Post Processing “Concept 3” (Trade off)
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Weight Reduction:
25 %
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“Original” vs “Concept 3” – Stiffness X
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Original Concept 3
≈ 3,8 mm ≈ 4,2 mm
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“Original” vs “Concept 3” – FBO Tension
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Original Concept 3
Max ≈ 750 MPa Max ≈ 1100 Mpa
(locally)
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Conclusion
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• Weight reduction of 25%
• Reduction of support area of 13%
• More investigations about stresses
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Further Works
Presentation title 23
1. Topology Optimization implementing of the thermal stresses, drag
forces, fatigue and unexpected loads on the TRS;
2. Performing the Topology Optimization at more sectors at the same
time because each sector has different stresses;
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24
Thanks for the attention