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Design for Additive Manufacturing Based Topology Optimization and Manufacturability Algorithms for Improved Part Build

Mhapsekar, Kunal Shekhar
http://orcid.org/0000-0002-8795-8734
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1535465547739089

Abstract Details

2018, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Significant advancements in the field of additive manufacturing (AM) have increased the popularity of AM in mainstream industries. Manufacturing feasibility and the dimensional accuracy of parts manufactured using AM depend on the part geometry and the accompanying process parameters. In order to create high quality functional products, both the part design and the process parameters need to be optimized for additive manufacturing processes. Build orientation is one of the most critical process parameters, since it has a direct impact on the part quality measurement metrics and the manufacturability concerns associated with AM. Designing parts for additive manufacturing (DFAM) and implementing those design considerations to determine the best build orientation can help achieve successful part builds. In addition to build orientation, optimization of the part designs based on DFAM principles can also significantly mitigate the manufacturability concerns in the early design stage. In this research, a weighted optimization model is presented to determine the optimum build orientation of a given part based on DFAM guidelines. These DFAM parameters include part geometric metrics such as cusp error, layer contour features such as thin features and sharp corners, and support structure parameters. A novel design optimization approach is proposed which integrates additive manufacturing constraints within a topology optimization framework. A density mapping based algorithm is developed for SIMP based topology optimization to minimize the growth of critically thin features in the optimized part design. Both these optimization models are validated with two test cases each. Improvements in the manufacturability metrics achieved using these algorithms prove the effectiveness of the proposed methodologies.
Sam Anand, Ph.D. (Committee Chair)
Michael Alexander-Ramos, Ph.D. (Committee Member)
Kumar Vemaganti, Ph.D. (Committee Member)
64 p.
Mechanical Engineering
Design for Additive Manufacturing; Part Build Orientation; Topology Optimization; Metal Additive Manufacturing; Thin Features

Recommended Citations

Citations

  • Mhapsekar, K. S. (2018). Design for Additive Manufacturing Based Topology Optimization and Manufacturability Algorithms for Improved Part Build [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1535465547739089

    APA Style (7th edition)

  • Mhapsekar, Kunal Shekhar. Design for Additive Manufacturing Based Topology Optimization and Manufacturability Algorithms for Improved Part Build. 2018. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1535465547739089.

    MLA Style (8th edition)

  • Mhapsekar, Kunal Shekhar. "Design for Additive Manufacturing Based Topology Optimization and Manufacturability Algorithms for Improved Part Build." Master's thesis, University of Cincinnati, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1535465547739089

    Chicago Manual of Style (17th edition)

ucin1535465547739089
584
© 2018, all rights reserved.
This open access ETD is published by University of Cincinnati and OhioLINK.