topology optimization

By integrating specific material properties through the manufacturing process Selective Laser Melting (SLM) into a topology optimization, the product engineer can be supported by simulation in the design process. For this purpose, a topology optimization method is being developed which takes the process-specific material properties of the SLM into account during the optimization process. This method is part of a project funded by the German Research Foundation (DFG). In this article, the influence of these specific material properties on the design is presented.

In this paper, the creation of strength and stiffness-adapted structural nodes using the numerical simulation method of topology optimization is presented. The resulting node is transferred into a robot path planning by means of CAD/CAM software and manufactured with wire arc additive manufacturing (WAAM) with the GMAW process using the welding filler material G4Si1.

For the production of pyrolysis models (wax models), which are used in the process of vacuum differential pressure casting, often silicone molds are used. These casting molds are manufactured by using rapid prototyping solid bodies. However, for the shaping only the outer shell is necessary. So the use of hollow bodies to the material and cost savings is possible. In this paper calculations and topology optimizations are presented at the example of a cylinder.

Structural optimization based on the finite elements method is a tool for the Design identification and optimization of technical structures within the product development process. Advantages are a substantial process acceleration by reducing classical “optimization loops” and the possibility to find solutions which are empirically not attainable. In the past, a disadvantage of the method was that the algorithms suggested partially drafts which were not or only at unacceptable costs producible. From this the motivation arose to develop the manufacturing restrictions for structural optimization tools, presented in the following. By means of these restrictions the solution area of the optimization will be limited to a given manufacturing method, so that optimized, producible drafts are developed.