Additive manufacturing of metallic components – Process, structure and properties

Topology optimization is the process of determining the optimal layout of material and connectivity inside a design domain. This paper surveys topology optimization of continuum structures from the year 2000 to 2012. It focuses on new developments, improvements, and applications of finite element-based topology optimization, which include a maturation of classical methods, a broadening in the scope of the field, and the introduction of new methods for multiphysics problems. Four different types of topology optimization are reviewed: (1) density-based methods, which include the popular Solid Isotropic Material with Penalization (SIMP) technique, (2) hard-kill methods, including Evolutionary Structural Optimization (ESO), (3) boundary variation methods (level set and phase field), and (4) a new biologically inspired method based on cellular division rules. We hope that this survey will provide an update of the recent advances and novel applications of popular methods, provide exposure to lesser known, yet promising, techniques, and serve as a resource for those new to the field. The presentation of each method's focuses on new developments and novel applications.

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A survey of structural and multidisciplinary continuum topology optimization: post 2000

Multi-scale computational homogenization: Trends and challenges

https://core.ac.uk/download/pdf/141091.pdf

Thermo-mechanical analysis of Wire and Arc Additive Layer Manufacturing process on large multi-layer parts

Modeling metal deposition in heat transfer analyses of additive manufacturing processes

We propose a new method for topology optimization, which is free from numerical instabilities such as checkerboard patterns and mesh-dependency, without introducing any additional constraint parameters. This aim is accomplished by the introduction of finite element approximation for continuous material distribution in a fixed design domain. That is, the continuous distribution of microstructures, or equivalently design variables, is realized in the whole design domain in the context of the homogenization design method (HDM), by the discretization with finite element interpolations. By virtue of this continuous FE approximation of design variables, discontinuous distribution like checkerboard patterns disappears without any filtering schemes. We call this technique the method of continuous approximation of material distribution (CAMD) to emphasize the continuity imposed on the "material field". Two representative numerical examples are presented to demonstrate the capability and the efficiency of the proposed approach against the numerical instabilities.

https://www.jstage.jst.go.jp/article/kikaia1979/69/684/69_684_1257/_pdf

Topology Optimization Method by Continuous Approximation of Material Distribution

Influence of the micro-structure of carbon steel on the yield stress and the properties of strain hardening

This research presents a structural topology optimization method for the design of mechanical resonators, and smart structures, such as mechanical actuators and sensors, that are composed of flexible structures and mechanical energy conversion devices. First, the concept of the topology optimization method is briefly discussed. Next, we clarify the mechanical design specifications of mechanical resonators, actuators and sensors, and construct objective functions that aim to satisfy design specifications. Based on these formulations, an optimization algorithm is constructed using Sequential Linear Programming (SLP). Finally, several numerical examples are presented in order to confirm that the method presented here can provide optimized structures applicable to the design of mechanical resonators, mechanical actuators and sensors.

Structural Topology Optimization of Mechanical Resonators, Actuators and Sensors

Structural Topology Optimization of Compliant Mechanisms Considering the Ratio of the Displacement at the Input Point to the Displacement at the Output Point

Kazumi Matsui

Papers

Topology Optimization Method by Continuous Approximation of Material Distribution

Influence of the micro-structure of carbon steel on the yield stress and the properties of strain hardening

Structural Topology Optimization of Mechanical Resonators, Actuators and Sensors

Structural Topology Optimization of Compliant Mechanisms Considering the Ratio of the Displacement at the Input Point to the Displacement at the Output Point

Introduction of pseudo-stress for local residual and algebraic derivation of consistent tangent in elastoplasticity