Topology optimisation for 3D printing
-
Upload
gilbert-peters -
Category
Technology
-
view
1.088 -
download
2
Transcript of Topology optimisation for 3D printing
Topology Optimisation2015
Want to know more about design for 3D printing, including Topology
Optimisation?
Contact us at: [email protected]
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
FransiscóSince 2009 | Design support for clients | 3D printed Adventure Motorcycle
Why 3D printing?Local production | Complex parts | Customer specific
Industrial revolutionSince 1800 | Begin mechanisation | Mass manufacturing | Limited design variables
Expensive toolingLarge investments required | Large production numbers | No customisation
Production linesLimited flexibility | Large investments required | Large production numbers
3D printing = goodbye big factories
But how to design for 3D printing?
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.”
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
Relevance for 3D printingOrganic complex shapes | Based upon bone growth | Lightweight & Stiff
Topology Optimisation design flow
Traditional design flowDesign
(CAD)CAE
Virtual test Build Test
RedesignRedesign
DesignOptimisation
Design(CAD)
CAEVirtual test Build Test
OptimisationResource savings
Working principleDefine contribution of elements | Test against optimisation criteria
F
Design goalsMinimum weight | Certain Eigen-frequency | Maximize stiffness @ weight %
Swingarm redesignOptimised for 3D printing in titanium
Design SpaceNon Design Space
Design spaceWhat can be optimised & what not
• Brake• Accelerate• Cornering• Obstacles
Load cases & functionalityWhat’s the use case of the component | This is the hard part
ResultsOptimised for maximum stiffness | Raw output | Resembles a bone | Large voids
2015 Additive World Award Winner
DetailingOrganic shapes | Integrated functionality
Benchmark
1part
16parts
Motorcycle swingarm redesignLess parts | Customised | Less machining | Brake system integration
GE Engine BracketDesign Challenge | +/- 700 entries | Simple load case & dimensions
Large variations700 different solutions to a ‘simple’ well defined problem
Person behind the buttons has huge influence
Market players
AltairEstablished name | Powerful engine | 3D printing mindset
Concept Engineer Simulation Engineer
For inspirational optimisation
studies
Industry standardIncreased
functionality, requires a specialist
AutodeskFocused on 3D printing | Generative Design | Lattice structures
CAD integrated Lattice structures
Lattice StructuresSupport for hollow structures | Dedicated analysis required
Dassault SystemsFE-Design | Abaqus – NASTRAN - ANSYS plugin
CAESSRequires PTC Creo | Plugin | Powerful cleanup tool | Lattice structures
Frustum CloudmeshRemote computing power | Lower upfront investment | Beta test Q4 2015
nTopology ElementLattice structures | Beta testing now running
Future DevelopmentsIncorporate 3D print rules, process & material | Integrate 3D CAD | Auto smoothing
• Use it for inspiration• Shorten
development time• Engineer still needed
Takeaways: