Manufacturing cost constrained topology optimization for additive manufacturing

doi:10.1007/s11465-019-0536-z

Front. Mech. Eng.

2019, Vol. 14

Issue (2) : 213-221 https://doi.org/10.1007/s11465-019-0536-z

RESEARCH ARTICLE

Manufacturing cost constrained topology optimization for additive manufacturing

Jikai LIU, Qian CHEN, Xuan LIANG, Albert C. TO(

)

Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261, USA

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Abstract

This paper presents a manufacturing cost constrained topology optimization algorithm considering the laser powder bed additive manufacturing process. Topology optimization for additive manufacturing was recently extensively studied, and many related topics have been addressed. However, metal additive manufacturing is an expensive process, and the high manufacturing cost severely hinders the widespread use of this technology. Therefore, the proposed algorithm in this research would provide an opportunity to balance the manufacturing cost while pursuing the superior structural performance through topology optimization. Technically, the additive manufacturing cost model for laser powder bed-based process is established in this paper and real data is collected to support this model. Then, this cost model is transformed into a level set function-based expression, which is integrated into the level set topology optimization problem as a constraint. Therefore, by properly developing the sensitivity result, the metallic additive manufacturing part can be optimized with strictly constrained manufacturing cost. Effectiveness of the proposed algorithm is proved by numerical design examples.

Keywords topology optimization manufacturing cost additive manufacturing powder bed

Corresponding Author(s): Albert C. TO

Just Accepted Date: 20 February 2019 Online First Date: 29 March 2019 Issue Date: 22 April 2019

Cite this article:

Jikai LIU,Qian CHEN,Xuan LIANG, et al. Manufacturing cost constrained topology optimization for additive manufacturing[J]. Front. Mech. Eng., 2019, 14(2): 213-221.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0536-z
https://academic.hep.com.cn/fme/EN/Y2019/V14/I2/213

Parameter	Value
$ρ$	4.42 g/cm³
$C material unit$	4500 USD/kg
$C argon unit$	5.13 USD/m³
$T R$	9 s
$L t$	0.06mm
$ρ ‾ / ρ$	0.4
$C labor unit + C utility unit$	120 USD/h
$T setup$	0.5 h
$S rate$	3.75 mm³/s

Tab.1 Data used for cost modeling

Fig.1 Design domain and boundary condition of the cantilever problem (size: 100×50)

Fig.2 Optimization results with different weight factors. (a)

w 1 = 1.0

; (b)

w 1 = 0.9

; (c)

w 1 = 0.7

; (d)

w 1 = 0.5

; (e)

w 1 = 0.3

Tab.2 Data of the cantilever optimization results (AM cost in USD if the dimension is measured in mm)

Fig.3 Cantilever design with constrain AM cost. (a) Level set representation of the design; (b) voxel view of the design (the yellow color shows the support volume)

Fig.4 Convergence history

Fig.5 Design domain and boundary condition of the L-bracket problem (size: 60×60×15)

Fig.6 Optimization result without cost constraint

Fig.7 Optimization result with cost constraint

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