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arXiv 2108.02829cs.CE
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可折叠支撑结构制造的拓扑优化

Topology Optimization for Manufacturing with Accessible Support Structures

Amir M. Mirzendehdel, Morad Behandish, Saigopal Nelaturi

摘要:

金属增材制造(AM)工艺通常制造近净形状,该近净形状包括所设计的部件以及需要通过减材制造(SM)(例如多轴加工)机加工掉的牺牲支撑结构。因此,尽管AM能够生成高度复杂的零件,但是由于铣削工具和工件之间可能的碰撞而导致的SM的限制可以使得优化的零件不可制造。我们提出了一个系统的方法来拓扑优化(TO)的AM其次是SM的部分,以确保可拆卸的支持结构,同时优化部分的性能。一个中心思想是使用一组给定的切削刀具组件和夹具方向,根据每个支撑结构点的可达性,从近净形状表达零件的生产率。我们的方法不会对零件、支撑结构、加工工具和夹具的几何复杂性施加任何人为约束。我们扩展了不可达性测度场(IMF)的概念,以支持结构来识别不可达点,并通过连续的空间场捕获它们对不可制造性的贡献。IMF然后被增强到灵敏度字段,以引导TO朝向可制造的设计。该方法通过寻找非平凡的复杂设计来实现高效和有效的设计空间探索,这些复杂设计的近净形状可以通过使用一组定制工具和夹具进行加工来进行3D打印和后处理以去除支撑。我们证明了我们的方法在2D和3D的非平凡的例子的有效性。

英文摘要:

Metal additive manufacturing (AM) processes often fabricate a near-net shape that includes the as-designed part as well as the sacrificial support structures that need to be machined away by subtractive manufacturing (SM), for instance multi-axis machining. Thus, although AM is capable of generating highly complex parts, the limitations of SM due to possible collision between the milling tool and the workpiece can render an optimized part non-manufacturable. We present a systematic approach to topology optimization (TO) of parts for AM followed by SM to ensure removability of support structures, while optimizing the part's performance. A central idea is to express the producibility of the part from the near-net shape in terms of accessibility of every support structure point using a given set of cutting tool assemblies and fixturing orientations. Our approach does not impose any artificial constraints on geometric complexity of the part, support structures, machining tools, and fixturing devices. We extend the notion of inaccessibility measure field (IMF) to support structures to identify the inaccessible points and capture their contributions to non-manufacturability by a continuous spatial field. IMF is then augmented to the sensitivity field to guide the TO towards a manufacturable design. The approach enables efficient and effective design space exploration by finding nontrivial complex designs whose near-net shape can be 3D printed and post-processed for support removal by machining with a custom set of tools and fixtures. We demonstrate the efficacy of our approach on nontrivial examples in 2D and 3D.

机构、总结、中文摘要均由AI分析而来,可能存在错误,请以论文正文为准。

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