Topology optimisation for 3D printing

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Topology Optimisation 2015

Transcript of Topology optimisation for 3D printing

Page 1: Topology optimisation for 3D printing

Topology Optimisation2015

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Want to know more about design for 3D printing, including Topology

Optimisation?

Contact us at: [email protected]

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Education:1999 – 2003: Bachelor Automotive Engineering2003 – 2007: Master Mechanical Engineering

Work experience:2007 – 2008: Inalfa Roofsystems Venray2009 – 2011: Stork Foodsystems2011 – 2014: SKF2009 – now: Fransiscó

in/GilbertPetersGilbert Peters

GilbertPetersNL @Fisco_GP

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FransiscóSince 2009 | Design support for clients | 3D printed Adventure Motorcycle

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Why 3D printing?Local production | Complex parts | Customer specific

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Industrial revolutionSince 1800 | Begin mechanisation | Mass manufacturing | Limited design variables

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Expensive toolingLarge investments required | Large production numbers | No customisation

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Production linesLimited flexibility | Large investments required | Large production numbers

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3D printing = goodbye big factories

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But how to design for 3D printing?

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Topology optimisation

“is a mathematical approach that optimises material layout within a given design space, for a given set of loads and boundary conditions

such that the resulting layout meets a prescribed set of performance

targets.”

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SizeOptimisation

Topology Optimisation

ShapeOptimisation

e.g. Thickness of a beam or X-section

e.g. Position of a hole

Complete shape, including holes

F F F

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Relevance for 3D printingOrganic complex shapes | Based upon bone growth | Lightweight & Stiff

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Topology Optimisation design flow

Traditional design flowDesign

(CAD)CAE

Virtual test Build Test

RedesignRedesign

DesignOptimisation

Design(CAD)

CAEVirtual test Build Test

OptimisationResource savings

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Working principleDefine contribution of elements | Test against optimisation criteria

F

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Design goalsMinimum weight | Certain Eigen-frequency | Maximize stiffness @ weight %

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Swingarm redesignOptimised for 3D printing in titanium

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Design SpaceNon Design Space

Design spaceWhat can be optimised & what not

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• Brake• Accelerate• Cornering• Obstacles

Load cases & functionalityWhat’s the use case of the component | This is the hard part

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ResultsOptimised for maximum stiffness | Raw output | Resembles a bone | Large voids

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2015 Additive World Award Winner

DetailingOrganic shapes | Integrated functionality

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Benchmark

1part

16parts

Motorcycle swingarm redesignLess parts | Customised | Less machining | Brake system integration

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GE Engine BracketDesign Challenge | +/- 700 entries | Simple load case & dimensions

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Large variations700 different solutions to a ‘simple’ well defined problem

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Person behind the buttons has huge influence

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Market players

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AltairEstablished name | Powerful engine | 3D printing mindset

Concept Engineer Simulation Engineer

For inspirational optimisation

studies

Industry standardIncreased

functionality, requires a specialist

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AutodeskFocused on 3D printing | Generative Design | Lattice structures

CAD integrated Lattice structures

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Lattice StructuresSupport for hollow structures | Dedicated analysis required

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Dassault SystemsFE-Design | Abaqus – NASTRAN - ANSYS plugin

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CAESSRequires PTC Creo | Plugin | Powerful cleanup tool | Lattice structures

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Frustum CloudmeshRemote computing power | Lower upfront investment | Beta test Q4 2015

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nTopology ElementLattice structures | Beta testing now running

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Future DevelopmentsIncorporate 3D print rules, process & material | Integrate 3D CAD | Auto smoothing

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• Use it for inspiration• Shorten

development time• Engineer still needed

Takeaways: