Concurrent Island scanning pattern and large-scale topology optimization method for laser powder bed fusion processed parts

Xu，Shuzhi1,2; Liu，Jikai1; Li，Xinming2; Ma，Yongsheng3

2023-11-01

10.1016/j.finel.2023.104018

Finite Elements in Analysis and Design   Impact Factor & Quartile

0168-874X

1872-6925

This paper proposes a numerical method for concurrent scanning pattern and topology optimization to design laser powder bed fusion (LPBF) processed large-scale parts. The method developed in this work is motivated by the emerging needs in design-for-LPBF metal additive manufacturing, to reduce the part residual warpage for manufacturability and enable the high-resolution structural details for performance. Specifically, the inherent strain-based process simulation solver is developed to predict the part-scale residual warpage induced by LPBF. Then, the concurrent scanning pattern and structural topology optimization algorithm is developed facilitated by the inherent strain solver and accelerated by the PETSc parallel-computing framework. The proposed approach is utilized to solve several 3D benchmark design cases to show its effectiveness in stiffness improvement and residual warpage reduction. The effects of varying the weighting coefficients and scanning patterns, and the importance of considering the concurrent optimization strategy are carefully investigated. The observed numerical phenomena are discussed to summarize the paper.

Inherent strain method Laser powder bed fusion Parallel computing Residual warpage Topology optimization

SCI

English

Corresponding

China Scholarship Council[202108180014];National Natural Science Foundation of China[52105462];Natural Science Foundation of Shandong Province[ZR2020QE165];

Mathematics ; Mechanics

Mathematics, Applied ; Mechanics

WOS:001071356900001

ELSEVIER

ENGINEERING

2-s2.0-85168798693

Scopus

1.School of Mechanical Engineering,Shandong University,Jinan,China
2.Department of Mechanical Engineering,University of Alberta,Edmonton,Canada
3.Department of Mechanical and Energy Engineering,Southern University of Science and Technology,Shenzhen,China

Xu，Shuzhi,Liu，Jikai,Li，Xinming,et al. Concurrent Island scanning pattern and large-scale topology optimization method for laser powder bed fusion processed parts[J]. Finite Elements in Analysis and Design,2023,225.

Xu，Shuzhi,Liu，Jikai,Li，Xinming,&Ma，Yongsheng.(2023).Concurrent Island scanning pattern and large-scale topology optimization method for laser powder bed fusion processed parts.Finite Elements in Analysis and Design,225.

Xu，Shuzhi,et al."Concurrent Island scanning pattern and large-scale topology optimization method for laser powder bed fusion processed parts".Finite Elements in Analysis and Design 225(2023).