Design for Additive Manufacturing Through Integration of Topology Optimization and Generative Design: A Case Study
摘要
Additive manufacturing (AM) is a layer-by-layer addition technology which have significant role in improving manufacturing process of automotive industries. Automotive component manufacturing industries have major objective of manufacturing lightweight components and also by maintaining optimal strength. Topology optimization (TO) is a mathematical approach of identifying optimal material distribution within the given domain using iterative algorithms. Generative design (GD) is another approach which supports artificial intelligence algorithms for generating various designs that meet the provided design criteria. Both approaches can optimize the component for reducing weight, costs and improving performance. But still there exists huge gap in the integration of TO and GD for producing lightweight components along with AM manufacturability constraints. This paper presents a framework for integrating TO and GD for optimizing lightweight structures with more functionality and manufacturability. The designs are then validated using finite element analysis. Redesign is carried out based on design for additive manufacturing (DfAM) rules and principles. The proposed framework is then applied to an automotive part. The results are then evaluated and compared with original design. Maximum stress induced by the part, maximum displacement and factor of safety are determined to ensure safe operating zones. The mass reduction of redesigned product is compared with the original design. Hence, integrating TO and GD can be an effective and efficient approach for generating lightweight products in automotive industries.