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Keywords: topology optimization, form finding, additive manufacturing, metal 3d printing, mathematical programming.

Abstract

Wire-and-Arc Additive Manufacturing (WAAM) is a metal 3d printing technique that allows fabricating elements ranging from simple geometry to extremely complex shapes. “Layer-by-layer” manufacturing produces a printed material with significant elastic anisotropy, whereas “dot-by-dot” printing may be used to fabricate funicular geometries in which the mechanical properties of the single bars are affected by the printing process. The design of WAAM components is addressed by formulating problems of structural optimizations that account for the peculiar features of the printed alloy. Topology optimization by distribution of anisotropic material is exploited to find optimal shapes in layer-by-layer manufacturing. Two-dimensional specimens are addressed along with I-beams. In the latter case it is assumed that a web plate and two flanges are printed and subsequently welded to assemble the structural component. A constrained force density method is proposed for the design of grid shells in dot-by-dot printing, formulating local enforcements to govern the magnitude of the axial force in each branch of the network. In both formulations, the arising multi-constrained problem is efficiently tackled through methods of sequential convex programming. Lightweight solutions for layer-by-layer and dot-by-dot manufacturing are found for given printing directions. Extensions of the proposed numerical tools are highlighted to endow he optimization problems with additional set of material-related constraints.

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Front Page Browse CCC CCP CSETS CTR IJRT Other Authors Search Purchase Guide FAQ Contact us	Civil-Comp Conferences ISSN 2753-3239 CCC: 3 PROCEEDINGS OF THE FOURTEENTH INTERNATIONAL CONFERENCE ON COMPUTATIONAL STRUCTURES TECHNOLOGY Edited by: B.H.V. Topping and J. Kruis Paper 2.1 Material-informed topology optimization for Wire-and-Arc Additive Manufacturing M. Bruggi¹, V. Laghi² and T. Trombetti² ¹Politecnico di Milano, Department of Civil and Environmental Engineering, Milano, Italy ²University of Bologna, Department of Civil, Chemical, Environmental and Materials Engineering, Bologna, Italy doi:10.4203/ccc.3.2.1 Full Bibliographic Reference for this paper M. Bruggi, V. Laghi, T. Trombetti, "Material-informed topology optimization for Wire-and-Arc Additive Manufacturing", in B.H.V. Topping, J. Kruis, (Editors), "Proceedings of the Fourteenth International Conference on Computational Structures Technology", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 3, Paper 2.1, 2022, doi:10.4203/ccc.3.2.1 Keywords: topology optimization, form finding, additive manufacturing, metal 3d printing, mathematical programming. Abstract Wire-and-Arc Additive Manufacturing (WAAM) is a metal 3d printing technique that allows fabricating elements ranging from simple geometry to extremely complex shapes. “Layer-by-layer” manufacturing produces a printed material with significant elastic anisotropy, whereas “dot-by-dot” printing may be used to fabricate funicular geometries in which the mechanical properties of the single bars are affected by the printing process. The design of WAAM components is addressed by formulating problems of structural optimizations that account for the peculiar features of the printed alloy. Topology optimization by distribution of anisotropic material is exploited to find optimal shapes in layer-by-layer manufacturing. Two-dimensional specimens are addressed along with I-beams. In the latter case it is assumed that a web plate and two flanges are printed and subsequently welded to assemble the structural component. A constrained force density method is proposed for the design of grid shells in dot-by-dot printing, formulating local enforcements to govern the magnitude of the axial force in each branch of the network. In both formulations, the arising multi-constrained problem is efficiently tackled through methods of sequential convex programming. Lightweight solutions for layer-by-layer and dot-by-dot manufacturing are found for given printing directions. Extensions of the proposed numerical tools are highlighted to endow he optimization problems with additional set of material-related constraints. download the full-text of this paper (PDF, 6 pages, 615 Kb) go to the previous paper go to the next paper return to the table of contents return to the volume description
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