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Towards Design Automation for Additive Manufacturing: A Multidisciplinary Optimization approach
Linköping University, Department of Management and Engineering, Machine Design. Linköping University, Faculty of Science & Engineering.
2019 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

In recent decades, the development of computer-controlled manufacturing by adding materiallayer by layer, called Additive Manufacturing (AM), has developed at a rapid pace. The technologyadds possibilities to the manufacturing of geometries that are not possible, or at leastnot economically feasible, to manufacture by more conventional manufacturing methods. AMcomes with the idea that complexity is free, meaning that complex geometries are as expensiveto manufacture as simple geometries. This is partly true, but there remain several design rulesthat needs to be considered before manufacturing. The research field Design for Additive Manufacturing(DfAM) consists of research that aims to take advantage of the possibilities of AMwhile considering the limitations of the technique.

Computer Aided technologies (CAx) is the name of the usage of methods and software thataim to support a digital product development process. CAx includes software and methodsfor design, the evaluation of designs, manufacturing support, and other things. The commongoal with all CAx disciplines is to achieve better products at a lower cost and with a shorterdevelopment time.

The work presented in this thesis bridges DfAM with CAx with the aim of achieving designautomation for AM. The work reviews the current DfAM process and proposes a new integratedDfAM process that considers the functionality and manufacturing of components. Selectedparts of the proposed process are implemented in a case study in order to evaluate theproposed process. In addition, a tool that supports part of the design process is developed.

The proposed design process implements Multidisciplinary Design Optimization (MDO) witha parametric CAD model that is evaluated from functional and manufacturing perspectives. Inthe implementation, a structural component is designed using the MDO framework, which includesComputer Aided Engineering (CAE) models for structural evaluation, the calculation ofweight, and how much support material that needs to be added during manufacturing. Thecomponent is optimized for the reduction of weight and minimization of support material,while the stress levels in the component are constrained. The developed tool uses methodsfor high level Parametric CAD modelling to simplify the creation of parametric CAD modelsbased on Topology Optimization (TO) results.

The work concludes that the implementation of CAx technologies in the DfAM process enablesa more automated design process with less manual design iterations than traditional DfAM processes.It also discusses and presents directions for further research to achieve a fully automateddesign process for Additive Manufacturing.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2019. , p. 53
Series
Linköping Studies in Science and Technology. Licentiate Thesis, ISSN 0280-7971 ; 1854
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:liu:diva-160888DOI: 10.3384/lic.diva-160888ISBN: 9789179299859 (print)OAI: oai:DiVA.org:liu-160888DiVA, id: diva2:1360761
Presentation
2019-10-04, Acas, Linköping, 10:15 (English)
Opponent
Supervisors
Projects
AddMan
Funder
Clean Sky 2, 738002Available from: 2019-10-14 Created: 2019-10-14 Last updated: 2019-10-15Bibliographically approved
List of papers
1. Design for additive manufacturing: a review of available design methods and software
Open this publication in new window or tab >>Design for additive manufacturing: a review of available design methods and software
2019 (English)In: Rapid prototyping journal, ISSN 1355-2546, E-ISSN 1758-7670, Vol. 25, no 6, p. 15p. 1080-1094Article, review/survey (Refereed) Published
Abstract [en]

Purpose

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.

Design/methodology/approach

The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.

Findings

Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.

Originality/value

The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.

Place, publisher, year, edition, pages
Emerald Group Publishing Limited, 2019. p. 15
Keywords
Additive manufacturing, Design automation, Design for additive manufacturing, Design optimization, Knowledge-based engineering
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:liu:diva-160357 (URN)10.1108/RPJ-10-2018-0262 (DOI)000482449200011 ()2-s2.0-85070356872 (Scopus ID)
Note

Funding agencies: European Union [738002]

Available from: 2019-09-19 Created: 2019-09-19 Last updated: 2019-11-28Bibliographically approved
2. AN OPTIMIZATION FRAMEWORK FOR ADDITIVE MANUFACTURING GIVEN TOPOLOGY OPTIMIZATION RESULTS
Open this publication in new window or tab >>AN OPTIMIZATION FRAMEWORK FOR ADDITIVE MANUFACTURING GIVEN TOPOLOGY OPTIMIZATION RESULTS
2018 (English)In: Tools and Methods of Competitive Engineering: Implementation, application and utilization of smart systems, 2018Conference paper, Published paper (Other academic)
Abstract [en]

In this paper, a method of designing for Additive Manufacturing (AM) is proposed, implemented, and evaluated in a case study. In the proposed method, Topological Optimization is combined with a Multidisciplinary Design Optimization (MDO) framework that handles multi-objective optimization. Both the weight and amount of support material needed during manufacturing are minimized. In the proposed method, the topological optimized structure is remodelled into a parametric CAD model. The CAD model is then combined with an FE-model that calculates the stresses in the material and a model that calculates the amount of support structure needed. Two different optimization formulations are evaluated and compared in the case study.

In the case study an upright of a Formula Student racing car is designed. Several design evaluations are performed resulting in a set of Pareto optimal designs that could be used for decision-making where the trade-off between the two objectives is considered. It is concluded that the proposed method fulfils its purpose by being able to identify designs that would be difficult to come up with manually. Several suggestions for further studies in order to improve the method are also discussed.

Keywords
Additive Manufacturing, Design for Additive Manufacturing, Topology Optimization, Design Optimization, Multidisciplinary Design Op
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:liu:diva-150367 (URN)
Conference
Twelfth International Symposium on Tools and Methods of Competitive Engineering (TMCE 2018), Las Palmas de Gran Canaria, Spain, 7-11 May 2018
Available from: 2018-08-20 Created: 2018-08-20 Last updated: 2019-10-14
3. Design for Additive Manufacturing using a Master Model approach
Open this publication in new window or tab >>Design for Additive Manufacturing using a Master Model approach
2019 (English)Conference paper, Published paper (Refereed)
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:liu:diva-160905 (URN)
Conference
Proceedings of the ASME 2019, International Design Engineering Technical Conferences, and Computers and Information in Engineering Conference IDETC/CIE2019, Anaheim, CA, USA, August 18 – 21, 2019
Available from: 2019-10-14 Created: 2019-10-14 Last updated: 2019-10-24Bibliographically approved

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