Chinese Journal of Lasers, Volume. 50, Issue 12, 1202301(2023)

Research Progress on Topology Optimization Design for Metal Additive Manufacturing

Boyu Liu1, Xiangming Wang2, Guang Yang1、*, and Bendong Xing2
Author Affiliations
  • 1School of Mechanic Engineering, Shenyang Aerospace University, Shenyang 110136, Liaoning, China
  • 2Shenyang Aircraft Design Institute, Aviation Industry Corporation of China, Shenyang 110035, Liaoning, China
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    Figures & Tables(13)
    Continuum structure topology optimization about cantilever beam. (a) Variable density method using HyperWorks; (b) evolutionary structural optimization method[19]; (c) level set method[20]; (d) moving morphable component method[21]; (e) feature-driven method[22]
    Numerical instability and improvement of topology optimization method based on elements
    Initial dependence and inability to open holes of level set method[44]. (a) 2 initial holes; (b) 9 initial holes; (c) 40 initial holes
    MBB beam level set topology optimization.(a) Topological gradient[45]; (b) PS-Kriging interpolation[55]
    Metal additive manufacturing technologies. (a)-(e) Schematics[75]; (f)-(j) products[73,76-78]
    Additive manufacturing printing failure[102]. (a) Assembly hole material collapse; (b) fracture of support structure; (c) internal support cannot be removed
    Topology optimization design for metal additive manufacturing
    Topology optimization considering minimum size constraint. (a) Nodal design variable and projection functions[105]; (b) robust formulation[106]; (c) spatial gradient operators[108]; (d) skeleton extraction and minimum feature optimization[12]
    MBB beam self-supporting optimization. (a) Overhang projection constraint[127]; (b) optimizing overhang angle and printing direction[21]; (c) polygon-featured holes[22]; (d) nonlinear virtual temperature method[128]
    Topology optimization considering connectivity constraints. (a) Virtual temperature method[102]; (b) shortest connection tunnels[131]; (c) side constraint[132]; (d) stress minimization[133]
    Topology optimization considering material anisotropy. (a) Strength anisotropy[14]; (b) quantified additive manufacturing process parameters[138]
    • Table 1. Common methods and characteristics of continuum structure topology optimization

      View table

      Table 1. Common methods and characteristics of continuum structure topology optimization

      Common methodAdvantageShortcoming
      Topology optimization based on elementsHomogenizationClassical method,mature principleRigorous mathematical model,existing optimal solutionComplex models,being difficult to implementMore intermediate density
      Variable densityFewer design variables,higher calculation efficiencyWidespread applicationExisting numerical instability
      Evolutionary structural optimizationPractical principle,simple algorithmAvoiding solving difficultiesMore iterations and lower calculation efficiencyExisting numerical instability
      Topology optimization based on boundary evolutionLevel setSimple principle,clear boundariesNo numerical instabilityStronger initial dependence,being unable to open holesWeaker convergence
      Moving morphable components/voidsFewer explicit design variables,higher calculation efficiencySeamless connection with CAD/CAE softwareClear boundariesStronger initial dependenceExisting unsmooth boundary
      Feature-drivenCollaborative design of features and topology optimizationFewer design variables,higher calculation efficiency,clear boundariesStronger dependence on characteristic number and layout
    • Table 2. Topology optimization common methods considering constraints of metal additive manufacturing

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      Table 2. Topology optimization common methods considering constraints of metal additive manufacturing

      ConstraintMethod based on elementMethod based on boundary evolutionProspect
      NameCharacteristicNameCharacteristic
      Geometric constraintsProjection functionsNo additional constraints,but boundary fading effectsSkeleton extractionSmooth convergence,but additional calculationNew methods with clear structure,stable convergence,and precise dimensional controlNew methods for specific additive manufacturing processes
      Robust formulationsStable convergence,eliminating one-node hinges,but more calculationQuadratic energy functionsHigh calculation efficiency,but not accurately controlling
      Spatial gradient operatorsLess calculation,but appropriate selections of parametersMMCExplicit geometry parameters,accurately controlling
      Forming constraintsProjection and filteringNo additional constraints,but more gray units;less calculation efficiencyGradient integral domainSimpler shape derivatives,better convergence and performanceSpecific additive manufacturing 3D models with overhang length and angleConsidering strength,building direction,size,and overhang constraints together
      N-VTMEnclosed voids self-supporting,better performanceMMC/MMVBetter boundary and performance,but initial dependency
      BESOConnecting voids with boundary,less structural lossOverhang length and angleControlling overhang length and angle,better performance
      ElectrostaticmodelStrength-based,improving stress concentrationSide constraintNo additional constraints,but appropriate selections of parameters
      Material property constraintsStrength anisotropyConsidering building direction to improve bearing capacityDeposition path planningFitting real print paths and improving structure performance based on fixed geometryAccurate anisotropic models for multiple additive manufacturing process parametersAccurate models for non-uniform deformationConsidering geometry’s influence on inherent strain value
      Quantified process parametersAnisotropic data matrix to optimize complex structures
      Inherent strain modelPredicting residual distortion and stress,but mainly improving layered distortion
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    Boyu Liu, Xiangming Wang, Guang Yang, Bendong Xing. Research Progress on Topology Optimization Design for Metal Additive Manufacturing[J]. Chinese Journal of Lasers, 2023, 50(12): 1202301

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    Paper Information

    Category: Laser Additive Manufacturing

    Received: Dec. 5, 2022

    Accepted: Mar. 23, 2023

    Published Online: Jun. 6, 2023

    The Author Email: Yang Guang (yangguang@sau.edu.cn)

    DOI:10.3788/CJL221485

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