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面向增减材复合制造的拓扑优化导热结构设计

Topology Optimization of Heat Conduction Structures for Hybrid Additive and Subtractive Manufacturing

  • 摘要: 为了实现增减材复合制造工艺下零件的可制造性和性能优化,提出一种面向先增后减复合制造工艺的结构拓扑优化方法.所提方法以热传导结构拓扑优化方法为基础,首先引入基于密度函数的增材滤波器,实现增材制造过程中悬垂面自支撑约束;然后引入基于对流扩散方程的多轴减材滤波器,满足多轴减材制造过程中的刀具可达性约束;所提算法能够完全消除增材制造中辅助支撑材料,达到提高材料利用率和降低后处理时间的目的,并且多轴减材制造工艺能够有效地提升零件表面质量与形状精度.通过二维和三维的传热结构算例,验证了所提方法的可制造性.

     

    Abstract: To achieve structure manufacturability and performance optimization in hybrid additive-subtractive manufacturing, this research proposed a topology optimization method for hybrid manufacturing with the “additive first, subtractive later” sequence. Based on the heat conduction structural topology optimization, this method introduced a density function-based additive manufacturing (AM) filter to satisfy the self-support constraint of overhanging surfaces during AM. In addition, we introduced a convection-diffusion equation-based multi-axis subtractive manufacturing (SM) filter to satisfy the tool accessibility constraint during multi-axis SM. The proposed algorithm reduced the amount of support material required in additive manufacturing and shortened the post-processing cost. Meanwhile, by integrating the multi-axis subtractive manufacturing process into the optimization, it effectively improved the surface quality and shape accuracy of structures. Finally, 2D and 3D heat conduction structure case studies were conducted to verify the manufacturability of the proposed topology optimization method for hybrid additive-subtractive manufacturing.

     

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