Topology optimization considering the distortion in additive manufacturing

• Published in: Finite elements in analysis and design Vol. 193; p. 103558
• Main Authors: Miki, Takao, Yamada, Takayuki
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.10.2021; Elsevier BV
• Subjects: Inherent strain method; Level set method; Metal additive manufacturing; Topology optimization; Inherent strain method; Topology optimization; Level set method; Metal additive manufacturing
• ISSN: 0168-874X; 1872-6925
• DOI: 10.1016/j.finel.2021.103558

Additive manufacturing is a free-form manufacturing technique in which parts are built in a layer-by-layer manner. Laser powder bed fusion is one of the popular techniques used to fabricate metal parts. However, it induces residual stress and distortion during fabrication that adversely affects the mechanical properties and dimensional accuracy of the manufactured parts. Therefore, predicting and avoiding the residual stress and distortion are critical issues. In this study, we propose a topology optimization method that accounts for the distortion. First, we propose a computationally inexpensive analytical model for additive manufacturing that uses laser powder bed fusion and formulated an optimization problem. Next, we approximate the topological derivative of the objective function using an adjoint variable method that is then utilized to update the level set function via a time evolutionary reaction-diffusion equation. Finally, the validity and effectiveness of the proposed optimization method was established using two-dimensional design examples. •A topology optimization method considering distortion induced by AM process.•Additive manufacturing (AM) process modeling based on the inherent strain method.•An inherent strain identification method and an experimental validation method.