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Accessibility of support structure in Topology Optimized Designs for Additive Manufacturing

Patil, Shriya Chetan
http://rave.ohiolink.edu/etdc/view?acc_num=ucin166863706556989

Abstract Details

2022, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Support structures are a vital part of generating lightweight topology-optimized designs for the Additive Manufacturing (AM) process. While it is possible to have zero support structures, this would limit potential part geometries and reduce performance. Hence, finding a well-balanced trade-off solution between minimum support structures and maximum performance is crucial. While support structures are necessary during the build process, they can result in wasted material and increased build times. Furthermore, the increased cost of removing support structures during post-processing should be considered. The reported literature presents methods to minimize support structures in topology-optimized designs. However, in most cases, the support structures may be blocked by part material and are inaccessible for removal during post-processing. Therefore, adding support accessibility criteria into the topology optimization algorithm would allow a support structure to be accessible from a predefined removal direction and reduce time wasted on post-processing as the entire support structure could be removable in just a few distinct part setups. This research introduces an updated support accessibility filter in conjunction with topology optimization to ensure that the supports in the final designs are removable from one or a combination of two directions along the coordinate axes. Using a combination of two directions (multi-directional) for support accessibility makes more support structures accessible for removal while keeping tool movements to a minimum. The orientation of the build plate with respect to part geometry affects the topology optimization of parts and the support structure required for building parts in that orientation. Therefore, adding the build plate's orientation and total support structure volume in combination with support accessibilities along different axis directions makes it possible to find the best trade-off solution between ease of support removal, support structure volume to be removed, and maximizing performance (minimum compliance).
Sam Anand, Ph.D. (Committee Member)
Xinyi Xiao, Ph.D. (Committee Member)
Manish Kumar, Ph.D. (Committee Member)
Michael Alexander-Ramos, Ph.D. (Committee Member)
78 p.
Mechanical Engineering
Additive Manufacturing; Topology Optimization; Support accessibility; Build plate orientation; Support structure removal; Multi-directional accessbility

Recommended Citations

Citations

  • Patil, S. C. (2022). Accessibility of support structure in Topology Optimized Designs for Additive Manufacturing [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin166863706556989

    APA Style (7th edition)

  • Patil, Shriya Chetan. Accessibility of support structure in Topology Optimized Designs for Additive Manufacturing. 2022. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin166863706556989.

    MLA Style (8th edition)

  • Patil, Shriya Chetan. "Accessibility of support structure in Topology Optimized Designs for Additive Manufacturing." Master's thesis, University of Cincinnati, 2022. http://rave.ohiolink.edu/etdc/view?acc_num=ucin166863706556989

    Chicago Manual of Style (17th edition)

ucin166863706556989
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This open access ETD is published by University of Cincinnati and OhioLINK.