Developments of Topology Optimization Methods for Additive Manufacturing involving High-cycle Fatigue

• Additive manufacturing (AM) is a versatile manufacturing process which is gaining popularity in the automotive and aerospace industries. Through AM one can manufacture complex structures and combined with topology optimization (TO) a powerful design tool that provides great freedom in geometric form emerges. The goal of the research presented in this thesis is to develop new TO methods that consider specific properties related to AM for metals. In particular, anisotropy, non-homogeneity in the form of surface effects, and constraints on high-cycle fatigue (HCF) damage are treated. In the first paper of the thesis, an HCF constraint is introduced into a TO problem where the total structural mass is minimized. The HCF model is based on a continuous-time approach in contrast to more conventional cycle-counting approaches. It is based on the concept of a moving endurance surface, and a system of ordinary differential equations is used to predict the fatigue damage at every point in the design domain. The model is capable of handling arbitrary load histories, including most non-proportional loads. Gradient-based optimization is utilized, and the fatigue sensitivities are determined by the adjoint method. In the subsequent papers, several extensions are made to the original HCFconstrained TO problem: The HCF model is extended so that it is applicable not only to isotropic materials but also to transversely isotropic materials. The anisotropic properties are manifested in the constitutive elastic response and in the fatigue properties. Acceleration of fatigue and sensitivity analyses by extrapolation is introduced, making the treatment of an unlimited number of load cycles possible. Simultaneous optimization of build orientation and topology, considering stress- and HCF constraints, is performed. For better prediction of fatigue, especially for non-proportional loads, the original continuous-time HCF model is modified using a quadratic polynomial endurance function. In the final paper, a new TO method, taking surface layer effects into account, is introduced. This essentially models the impaired mechanical properties observed in as-built AM components compared to components having polished surfaces. Numerical test problems as well as application-like problems are solved in all papers to exemplify the applicability of the developed TO methodology. 

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik -- Teknisk mekanik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering -- Applied Mechanics (hsv//eng)

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