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Modular-topology optimization for additive manufacturing of reusable mechanisms
Computers & Structures ( IF 4.4 ) Pub Date : 2024-12-20 , DOI: 10.1016/j.compstruc.2024.107630
Marek Tyburec, Martin Doškář, Michael Somr, Martin Kružík, Jan Zeman

Modular designs have gained popularity because they can generally address manufacturing efficiency, reusability, and sustainability concerns. Here, we contribute to the growing field by proposing a fully automatic design method for modules utilized in several products. Our manufacturing-aware procedure is composed of three consecutive steps: (i) free-material optimization for obtaining the optimal spatially distributed elasticity tensors, (ii) hierarchical clustering of the stiffness tensors directly into a given number of modules while allowing for their flipping, and (iii) single-scale topology optimization with manufacturing aspects to design the final topology of mechanically compatible modules. These aspects include connectivity constraints to ensure the integrity of all modules and the three-field projection to account for manufacturing inaccuracies. We illustrate the entire procedure with the design and fabrication of eight different reusable modules assembled into well-functioning modular inverter and gripper mechanisms. These mechanisms were 3D printed and subjected to mechanical testing using an in-house testing machine and digital image correlation. The experimental results show excellent agreement between the predicted and observed behavior and highlight the potential of the method for scalable additive manufacturing.

中文翻译:


用于可重复使用机构增材制造的模块化拓扑优化



模块化设计越来越受欢迎,因为它们通常可以解决制造效率、可重用性和可持续性问题。在这里,我们通过为多种产品中使用的模块提出一种全自动设计方法,为不断发展的领域做出贡献。我们的制造感知程序由三个连续的步骤组成:(i) 自由材料优化以获得最佳空间分布弹性张量,(ii) 刚度张量的分层聚类直接到给定数量的模块中,同时允许它们翻转,以及 (iii) 具有制造方面的单尺度拓扑优化,以设计机械兼容模块的最终拓扑。这些方面包括确保所有模块完整性的连接约束,以及用于解决制造不准确性的三场投影。我们通过设计和制造八个不同的可重复使用模块来说明整个过程,这些模块组装成功能良好的模块化逆变器和夹爪机构。这些机构是 3D 打印的,并使用内部测试机和数字图像相关技术进行机械测试。实验结果表明,预测行为和观察到的行为之间非常一致,并突出了该方法在可扩展增材制造方面的潜力。
更新日期:2024-12-20
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