大规模增材制造的拓扑优化：生成针对沉积喷嘴尺寸的设计
Topology Optimization for Large-Scale Additive Manufacturing: Generating designs tailored to the deposition nozzle size
摘要：
用于大规模组件的增材制造（AM）工艺沉积大量材料以缩短工艺持续时间。这降低了AM工艺的分辨率，其通常由沉积喷嘴的尺寸限定。如果在设计大规模增材制造（LSAM）时不考虑分辨率限制，则在制造过程中可能会出现困难，这可能需要调整沉积参数。这项工作将喷嘴的尺寸约束到拓扑优化（TO），以产生适合的工艺分辨率的优化设计。本文提出并比较了两种方法，这是基于现有的TO技术，使控制的最小和最大构件尺寸，以及最小空腔尺寸。第一种方法要求最小和最大构件尺寸等于沉积喷嘴尺寸，从而在优化设计中获得均匀宽度的设计特征。第二种方法将固体构件的尺寸限定得足够小，以使所得结构类似于结构骨架，这可以被解释为沉积路径。通过过滤和投影技术，薄结构根据所选喷嘴尺寸变厚。因此，与沉积方案一起获得了针对沉积喷嘴的尺寸定制的拓扑结构。使用2D和3D基准问题的方法进行了演示和评估。
英文摘要：
Additive Manufacturing (AM) processes intended for large scale components deposit large volumes of material to shorten process duration. This reduces the resolution of the AM process, which is typically defined by the size of the deposition nozzle. If the resolution limitation is not considered when designing for Large-Scale Additive Manufacturing (LSAM), difficulties can arise in the manufacturing process, which may require the adaptation of the deposition parameters. This work incorporates the nozzle size constraint into Topology Optimization (TO) in order to generate optimized designs suitable to the process resolution. This article proposes and compares two methods, which are based on existing TO techniques that enable control of minimum and maximum member size, and of minimum cavity size. The first method requires the minimum and maximum member size to be equal to the deposition nozzle size, thus design features of uniform width are obtained in the optimized design. The second method defines the size of the solid members sufficiently small for the resulting structure to resemble a structural skeleton, which can be interpreted as the deposition path. Through filtering and projection techniques, the thin structures are thickened according to the chosen nozzle size. Thus, a topology tailored to the size of the deposition nozzle is obtained along with a deposition proposal. The methods are demonstrated and assessed using 2D and 3D benchmark problems.
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