Efficient Design-Optimization of Variable-Density Hexagonal Cellular Structure by Additive Manufacturing: Theory and Validation


Zhang P., TOMAN J., YU Y., BIYIKLI E., Kırca M., CHMIELUS M., ...More

JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME, vol.137, no.2, 2015 (SCI-Expanded) identifier identifier

  • Publication Type: Article / Article
  • Volume: 137 Issue: 2
  • Publication Date: 2015
  • Doi Number: 10.1115/1.4028724
  • Journal Name: JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus
  • Keywords: cellular structure, additive manufacturing, design for manufacturing, modeling and simulation, MECHANICAL-PROPERTIES, METAL FABRICATION, LASER, IMPLANTS, STIFFNESS, STRENGTH
  • Istanbul Technical University Affiliated: Yes

Abstract

Cellular structures are promising candidates for additive manufacturing (AM) due to their lower material and energy consumption. In this work, an efficient method is proposed for optimizing the topology of variable-density cellular structures to be fabricated by certain AM process. The method gains accuracy by relating the cellular structure's microstructure to continuous micromechanics models and achieves efficiency through conducting continuum topology optimization at macroscopic scale. The explicit cellular structure is then finally reconstructed by mapping the optimized continuous parameters (e.g., density) to cell structural parameters (e.g., strut diameter). The proposed method is validated by both finite element analysis and experimental tests on specimens manufactured by stereolithography.