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<p>This study presents a hybrid structure optimization methodology that integrates topology optimization with lattice structure optimization. The proposed methodology aims to optimize lightweight and mechanically performing structures suitable for additive manufacturing. In traditional topology optimization processes, weight reduction is limited due to the occurrence of non-manufacturable intermediate density regions. As a pragmatic solution to this limitation, the optimum solid topology determined by topology optimization was combined with the optimum lattice structure determined by lattice structure optimization. Thus, has been obtained variable density hybrid structure capable of manufacturing intermediate density regions. In the optimization process carried out with the AlSi10Mg alloy, the proposed hybrid structure optimization approach Lightened the design by 10.75% and increased the specific strength by 12.03% compared to the topology optimization performed with the SIMP model. In addition, the heat treatment applied resulted in a 27.84% increase in the toughness of hybrid structure compared to topology optimized structure. Hybrid structure optimization applied to the torque Link of helicopter main landing gear components Lightened weight by 64.6% but only was observed 2.6% decrease in maximum load carrying capacity. As a result, the hybrid structure optimization methodology proposed has been experimentally validated and successfully applied to component used in the aerospace industry.</p>

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Hybrid structure optimization approach in additive manufacturing and its application to Torque link

  • 期刊论文

  • 发表日期：

    2025年9月4日

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  • Fehmi Mutlu,
  • Mehmet Cengiz Kayacan

摘要

This study presents a hybrid structure optimization methodology that integrates topology optimization with lattice structure optimization. The proposed methodology aims to optimize lightweight and mechanically performing structures suitable for additive manufacturing. In traditional topology optimization processes, weight reduction is limited due to the occurrence of non-manufacturable intermediate density regions. As a pragmatic solution to this limitation, the optimum solid topology determined by topology optimization was combined with the optimum lattice structure determined by lattice structure optimization. Thus, has been obtained variable density hybrid structure capable of manufacturing intermediate density regions. In the optimization process carried out with the AlSi10Mg alloy, the proposed hybrid structure optimization approach Lightened the design by 10.75% and increased the specific strength by 12.03% compared to the topology optimization performed with the SIMP model. In addition, the heat treatment applied resulted in a 27.84% increase in the toughness of hybrid structure compared to topology optimized structure. Hybrid structure optimization applied to the torque Link of helicopter main landing gear components Lightened weight by 64.6% but only was observed 2.6% decrease in maximum load carrying capacity. As a result, the hybrid structure optimization methodology proposed has been experimentally validated and successfully applied to component used in the aerospace industry.