Submitted:
03 June 2024
Posted:
04 June 2024
You are already at the latest version
Abstract
Keywords:
1. Introduction
2. Case Study
- Minimum solid phase length of 2.4 mm: This constraint ensures that features smaller than 6 times the size of the extruded material are avoided, given the typical nozzle pick diameter of an FDM printer is 0.4 mm.
- Symmetry in the YZ plane: While forces are symmetrical with respect to this plane, ensuring symmetric results is essential for consistent behaviour and stiffness across both sides of the front fork. This plane is represented in green in Figure 2.
- Extrusion in Z-direction: To maintain comparability across different software packages, an extrusion constraint is applied as a 90° overhang constraint. Although overhang angle is a common constraint in topology optimization for additive manufacturing, its implementation varies among software packages. In this case, the geometry of the part makes it suitable for this constraint due to its small thickness relative to other dimensions.
3. MATLAB Implementation
3.1. Geometry and Design Space Implementation
- Void space: The density of the elements is always 0. It defines the shape of the initial design of the triple-tree and does not influence the structural calculations. It is formed by passive elements.
- Non-design space: It encompasses volumes that must remain the same at the end of the optimization process. The density of the elements inside these volumes is always 1, and they do influence the structural calculations. It is constituted by active elements.
- Design space: The density of the elements vary from 0 to 1 with intermediate values adhering to a density-based approach topology optimization. The volume constraint defined in Equation 2 is applied only to this space, as is the only space that can vary its design variables in every iteration.
3.2. Heaviside Step Function
3.3. Parameters Update Algorithm
- The algorithm begins operation in the 201st iteration, allowing the algorithm to create an initial design.
- Condition 1 compares the maximum density change of the last 50 iterations. If the median value is near the maximum permitted change, the condition is satisfied. It can be expressed as in Equation 8:
- Condition 2 compares the same change value of the last 50 with the last 100 iterations. If the median change in both scenarios is similar, the condition is satisfied. It can be expressed as in Equation 9:
- Loopvol is a counter that prevents consecutive parameter updates. It is restarted when the parameters are updated and must surpass 25 for the next parameters update.
- must stay under 1 to maintain a relatively high discreteness.
- Volfrac is the actual iteration volume fraction following Equation 2.
- Volfracref is the prescribed volfrac upper limit described in Equation 1.
- In Parameters Update 1, the parameter is set to 1, and a new parameter “Volfracobj” is introduced. Volfracobj is the value that Volfrac takes as a reference for the OC routine when Parameters Update 1 is activated. Initially matching Voldracref, it reduces Volfracobj whenever Parameters Update 1 is active until reaching a minimum of Voldracref-0.05. Additionally, all the loop counter variables are restarted and the is also restarted to a value of 1.
- In Parameters Update 2, Volfrac is expanded by 0.005. Note that this update occurs when Volfrac<Volfracref, so Volfrac increases until matching Volfracref, thereby triggering Parameters Update 1 instead of Parameters Update 2. Additionally, the is expanded by 0.5 and the parameter is halved.
4. Software Packages Configuration
5. Results
6. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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| Software | Mesh Information | Objective | Constraints | Geom. Restrictions | Sim.Time (HH:mm:ss) |
|---|---|---|---|---|---|
| HyperMesh 2023.1 | 491809 CTETRA elements. Mesh size = 2.5. | Minimize compliance. | Volumefrac upper limit = 0.3. | Mindim = 2.4. Pattern grouping = 1 pln sym. No twist extrusion. |
00:29:29 |
| Parametric 6.0.1.0 | 433488 Tetrahedrons. Mesh size = 1.98 mm. |
Minimize strain energy. | Mass fraction upper limit 0.3. | Extrude along Z axis. Mirror about YZ plane. Minimum member size = 2.4. |
00:25:45 |
| SolidWorks 2023 | Default mesh 2 mm size. 349368 elements | Best stiffness-to-weight ratio. | 70% mass reduction. | Thickness control – min = 4 mm. Symmetry control. De-mold direction – Stamping (pull direction only). |
00:59:12 |
| Workbench 2023 R1 | 467009 Tetrahedrons. Mesh size = 2.2 mm. | Minimize compliance. | Volume constraint – 30% retain. | Member size – Min Size = 2.4 mm. Symmetry design constraint. Extrusion. |
00:52:57 |
| Software | Volume Fraction | Max. Displacement | Advantages | Disadvantages |
|---|---|---|---|---|
| HyperMesh 2023.1 | 31.956% | 4.055·10-2 mm | Accurate with objective and constraints. Good discreteness. |
Symmetry constraint violated in low densities. Slight volume fraction constraint violation. |
| CREO Parametric 6.0.1.0 | 36.475% | 3.825·10-2 mm | Well defined and simple shape. | General instabilities in result. Lack of high-density elements. Volume fraction constraint violation. |
| SolidWorks 2023 | 46.117% | 3.529·10-2 mm | Best discreteness in software packages | High volume fraction constraint violation. |
| ANSYS Workbench 2023 R1 | 35.929% | 3.629·10-2 mm | Best calculation performance in software packages. | Low density features. Volume fraction constraint violation. Lack of continuity in high density range. |
| MATLAB | 29.540% | 4.674·10-2 mm |
=1.386) Didn’t violate volume fraction constraint. Simulation time significantly lower: 00:03:02 |
Harder geometry introduction to the algorithm. Improve mesh definition, which would increase calculation time. |
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