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Titanium cholla : lightweight, high-strength structures for aerospace applications

Gill, David D.; Atwood, Clinton J.; Robbins, Joshua R.; Voth, Thomas E.

Aerospace designers seek lightweight, high-strength structures to lower launch weight while creating structures that are capable of withstanding launch loadings. Most 'light-weighting' is done through an expensive, time-consuming, iterative method requiring experience and a repeated design/test/redesign sequence until an adequate solution is obtained. Little successful work has been done in the application of generalized 3D optimization due to the difficulty of analytical solutions, the large computational requirements of computerized solutions, and the inability to manufacture many optimized structures with conventional machining processes. The Titanium Cholla LDRD team set out to create generalized 3D optimization routines, a set of analytically optimized 3D structures for testing the solutions, and a method of manufacturing these complex optimized structures. The team developed two new computer optimization solutions: Advanced Topological Optimization (ATO) and FlexFEM, an optimization package utilizing the eXtended Finite Element Method (XFEM) software for stress analysis. The team also developed several new analytically defined classes of optimized structures. Finally, the team developed a 3D capability for the Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) additive manufacturing process including process planning for 3D optimized structures. This report gives individual examples as well as one generalized example showing the optimized solutions and an optimized metal part.

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Topology Optimization of Cellular Structure

Robbins, Joshua R.; Owen, Steven J.; Clark, Brett W.; Voth, Thomas E.

This paper presents an end-to-end design process for compliance minimization based topological optimization of cellular structures through to the realization of a final printed product. Homogenization is used to derive properties representative of these structures through direct numerical simulation of unit cell models of the underlying periodic structure. The resulting homogenized properties are then used assuming uniform distribution of the cellular structure to compute the final macro-scale structure. A new method is then presented for generating an STL representation of the final optimized part that is suitable for printing on typical industrial machines. Quite fine cellular structures are shown to be possible using this method as compared to other approaches that use nurb based CAD representations of the geometry. Finally, results are presented that illustrate the fine-scale stresses developed in the final macro-scale optimized part and suggestions are made as to incorporate these features into the overall optimization process.

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Topology Optimization with a Manufacturability Objective

Robbins, Joshua R.

Part distortion and residual stress are critical factors for metal additive manufacturing (AM) because they can lead to high failure rates during both manufacturing and service. We present a topology optimization approach that incorporates a fast AM process simulation at each design iteration to provide predictions of manufacturing outcomes (i.e., residual stress, distortion, residual elastic energy) that can be optimized or constrained. The details of the approach and implementation are discussed, and an example design is presented that illustrates the efficacy of the method.

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Wave propagation and dispersion in elasto-plastic microstructured materials

International Journal of Solids and Structures

Dingreville, Rémi; Robbins, Joshua R.; Voth, Thomas E.

A Mindlin continuum model that incorporates both a dependence upon the microstructure and inelastic (nonlinear) behavior is used to study dispersive effects in elasto-plastic microstructured materials. A one-dimensional equation of motion of such material systems is derived based on a combination of the Mindlin microcontinuum model and a hardening model both at the macroscopic and microscopic level. The dispersion relation of propagating waves is established and compared to the classical linear elastic and gradient-dependent solutions. It is shown that the observed wave dispersion is the result of introducing microstructural effects and material inelasticity. The introduction of an internal characteristic length scale regularizes the ill-posedness of the set of partial differential equations governing the wave propagation. The phase speed does not necessarily become imaginary at the onset of plastic softening, as it is the case in classical continuum models and the dispersive character of such models constrains strain softening regions to localize. © 2014 Elsevier Ltd. All rights reserved.

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Results 51–69 of 69
Results 51–69 of 69