The document investigates the effect of different internal structures for parts fabricated using fused deposition modeling. Finite element analysis and experiments were conducted to validate the accuracy of the simulation. Topology optimization was used to design improved internal structures. Results showed that for low pressure, sparse double dense structure had higher displacement than solid, while topology optimization was closer to solid. For high pressure, topology optimization had much lower stress than other structures, though it had longer build time. The study validated the simulation accuracy and provided guidance on choosing internal structures.
Asphalt mixtures are made up of aggregates, binder and air voids. In order to make a economic and satisfactory performing asphalt mixture the quantity of these individual constituent is required. Mixture design is a tool to determine these optimum quantities.
A Review on Various Approach for Process Parameter Optimization of Burnishing...ijsrd.com
The aim of this paper is review for different optimization methods used for process parameter optimization of roller burnishing process and Taguchi approach used for process parameter optimization for various processes. The quality of burnishing processed parts are highly depends upon various process parameters of burnishing process. Hence optimization of burnishing process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of burnishing process and application of Taguchi approach for design of experiments.
The selection of optimal cutting parameters in turning operation is very important to
achieve high cutting performance. This paper deals with the optimization of performance
characteristics of turning EN-16 steel alloy using tungsten carbide inserts by Taguchi approach. The
experiments were performed on the basis of an L-18 orthogonal array given by Taguchi’s parameter
design approach. The performance characteristics such as thrust force and Material Removal Rate
(MRR) are optimized with the optimal combination of cutting parameters such as nose radius,
cutting speed, feed rate and depth of cut. Analysis of variance (ANOVA) is applied to identify the
most significant factor using MINITAB-16 software. The cutting parameters are varied to observe
the effects on performance characteristics and find the optimal results. Finally, confirmation tests are
performed to verify the experimental results. The results from the confirmation tests proved that the
performance characteristics such as thrust force and MRR are improved simultaneously through
optimal combination of process parameters obtained from Taguchi approach
Asphalt mixtures are made up of aggregates, binder and air voids. In order to make a economic and satisfactory performing asphalt mixture the quantity of these individual constituent is required. Mixture design is a tool to determine these optimum quantities.
A Review on Various Approach for Process Parameter Optimization of Burnishing...ijsrd.com
The aim of this paper is review for different optimization methods used for process parameter optimization of roller burnishing process and Taguchi approach used for process parameter optimization for various processes. The quality of burnishing processed parts are highly depends upon various process parameters of burnishing process. Hence optimization of burnishing process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of burnishing process and application of Taguchi approach for design of experiments.
The selection of optimal cutting parameters in turning operation is very important to
achieve high cutting performance. This paper deals with the optimization of performance
characteristics of turning EN-16 steel alloy using tungsten carbide inserts by Taguchi approach. The
experiments were performed on the basis of an L-18 orthogonal array given by Taguchi’s parameter
design approach. The performance characteristics such as thrust force and Material Removal Rate
(MRR) are optimized with the optimal combination of cutting parameters such as nose radius,
cutting speed, feed rate and depth of cut. Analysis of variance (ANOVA) is applied to identify the
most significant factor using MINITAB-16 software. The cutting parameters are varied to observe
the effects on performance characteristics and find the optimal results. Finally, confirmation tests are
performed to verify the experimental results. The results from the confirmation tests proved that the
performance characteristics such as thrust force and MRR are improved simultaneously through
optimal combination of process parameters obtained from Taguchi approach
Compliant polishing tools are utilized incomprehensibly as a part of vehicle and aviation businesses to clean complex surfaces and structures. The major advantages of using coated abrasive tools are that they are compliant and their geometry conforms to the surface of the workpiece. Though they have been used for finishing operations for a long time, not much work has been done to understand the effect of compliance on the distribution of forces in the contact area of such tools. Such understanding would help to reduce the trial and error operations involved and thereby reducing rework and cost.
The objectives of this study are as follows:
1) Study the effect of tool (rubber pad and abrasive cloth) compliance on contact pressure distribution and material removal of commonly used compliant polishing tools
2) The tool compliance is in turn studied by conducting material characterization; along with the geometry of the workpiece, other machining parameters are the key variables in this study
3) Design and analyze an active complaint finishing tool
The Marshall stability and flow test provides the performance prediction measure for the Marshall mix design method. The stability portion of the test measures the maximum load supported by the test specimen at a loading rate of 50.8 mm/minute. Load is applied to the specimen till failure, and the maximum load is designated as stability. During the loading, an attached dial gauge measures the specimen's plastic flow (deformation) due to the loading. The flow value is recorded in 0.25 mm (0.01 inch) increments at the same time when the maximum load is recorded.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Evaluation on Low Temperature Performance of Recycled Asphalt Mixture Using W...IJERA Editor
In this paper, the basic idea is about the recycled technology of asphalt mixture, more in-depth study of the low-temperature performance of warm mix asphalt(WMA).First of all, Including the evaluation of low temperature performance of WMA made of reclaimed asphalt pavement (RAP) (passed and not passed 2.36mm screen), and the influence of WMA with RAP mixed of different dosage of dispersant. Then, using the SBS modified asphalt and base asphalt were test at low temperature, research on the influence of different type of asphalt to the low temperature performance of WMA.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Rolling Case study
manipulating rolling parameters to enhance rolling process.
--------------------------------------------------------------------------
The main interest of this study is to see how to reduce contact pressure by the changing of rolling process factors.
Reducing von-mises stresses and contact pressure by simulating rolling process and finding optimum rolling parameters (the roller speed and the diameter of the roller )
Stiffened Panels structures are widely used because they make the structure more cost-effective by offering a desirable strength/weight ratio, and is in so far that even small weight reduction of each of them can significantly affect the total empty weight of the structure. The reduction in the structural weight of ships gives valuable advantages such as; increasing their cargo-carrying efficiency, decrease in material cost supersedes the higher production costs, also lighter vessels requires engines with lower power, which means less emission of hazardous gases produced by marine diesel engines.
In this research a barge’s deck is evaluated by means of finite element analysis and optimized by parametric sensitivity analysis and numerical optimization methods, and the results would show that the deck structure could be developed further by utilizing the optimization techniques to reduce their weight by up to 9%.
Stress and Durability Analysis of Threaded Connections in a Cast Aluminum Cyl...Altair
Bolted connections involve sharp notched components that are therefore sensitive to fatigue loading. In internal combustion engines, the journal bearings of the crankshaft are supported by bearing caps which are bolted to the cylinder block. These threaded connections are a fatigue concern as cracking may be experienced on dynamometer tests of new engines. The critical element of this application however is not the steel studs rather the threaded bolt holes in the cast engine block. While the nominal stress concept is applicable to the fatigue design of studs, a local stress approach has to be adopted to assess the fatigue strength of threaded bolt holes.
This paper addresses the fatigue design of this kind of threaded connection. Initially alternate methods of FE modeling and analysis of threaded joints by the local approach are critically examined. The parallel development of a simplified experimental test system involving a threaded hole in cast AlSi7 is described and used to generate baseline fatigue data under known loading conditions. The fatigue behavior of the experimental system is then analyzed on the basis of alternate FE models and post processing approaches. Finally, recommendations for the accurate and computationally efficient FE modeling and durability analysis of threaded connections in cast aluminum cylinder block are outlined.
Speakers
Marco Bersella, Engineer, TP Engineering srl
Compliant polishing tools are utilized incomprehensibly as a part of vehicle and aviation businesses to clean complex surfaces and structures. The major advantages of using coated abrasive tools are that they are compliant and their geometry conforms to the surface of the workpiece. Though they have been used for finishing operations for a long time, not much work has been done to understand the effect of compliance on the distribution of forces in the contact area of such tools. Such understanding would help to reduce the trial and error operations involved and thereby reducing rework and cost.
The objectives of this study are as follows:
1) Study the effect of tool (rubber pad and abrasive cloth) compliance on contact pressure distribution and material removal of commonly used compliant polishing tools
2) The tool compliance is in turn studied by conducting material characterization; along with the geometry of the workpiece, other machining parameters are the key variables in this study
3) Design and analyze an active complaint finishing tool
The Marshall stability and flow test provides the performance prediction measure for the Marshall mix design method. The stability portion of the test measures the maximum load supported by the test specimen at a loading rate of 50.8 mm/minute. Load is applied to the specimen till failure, and the maximum load is designated as stability. During the loading, an attached dial gauge measures the specimen's plastic flow (deformation) due to the loading. The flow value is recorded in 0.25 mm (0.01 inch) increments at the same time when the maximum load is recorded.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Evaluation on Low Temperature Performance of Recycled Asphalt Mixture Using W...IJERA Editor
In this paper, the basic idea is about the recycled technology of asphalt mixture, more in-depth study of the low-temperature performance of warm mix asphalt(WMA).First of all, Including the evaluation of low temperature performance of WMA made of reclaimed asphalt pavement (RAP) (passed and not passed 2.36mm screen), and the influence of WMA with RAP mixed of different dosage of dispersant. Then, using the SBS modified asphalt and base asphalt were test at low temperature, research on the influence of different type of asphalt to the low temperature performance of WMA.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Rolling Case study
manipulating rolling parameters to enhance rolling process.
--------------------------------------------------------------------------
The main interest of this study is to see how to reduce contact pressure by the changing of rolling process factors.
Reducing von-mises stresses and contact pressure by simulating rolling process and finding optimum rolling parameters (the roller speed and the diameter of the roller )
Stiffened Panels structures are widely used because they make the structure more cost-effective by offering a desirable strength/weight ratio, and is in so far that even small weight reduction of each of them can significantly affect the total empty weight of the structure. The reduction in the structural weight of ships gives valuable advantages such as; increasing their cargo-carrying efficiency, decrease in material cost supersedes the higher production costs, also lighter vessels requires engines with lower power, which means less emission of hazardous gases produced by marine diesel engines.
In this research a barge’s deck is evaluated by means of finite element analysis and optimized by parametric sensitivity analysis and numerical optimization methods, and the results would show that the deck structure could be developed further by utilizing the optimization techniques to reduce their weight by up to 9%.
Stress and Durability Analysis of Threaded Connections in a Cast Aluminum Cyl...Altair
Bolted connections involve sharp notched components that are therefore sensitive to fatigue loading. In internal combustion engines, the journal bearings of the crankshaft are supported by bearing caps which are bolted to the cylinder block. These threaded connections are a fatigue concern as cracking may be experienced on dynamometer tests of new engines. The critical element of this application however is not the steel studs rather the threaded bolt holes in the cast engine block. While the nominal stress concept is applicable to the fatigue design of studs, a local stress approach has to be adopted to assess the fatigue strength of threaded bolt holes.
This paper addresses the fatigue design of this kind of threaded connection. Initially alternate methods of FE modeling and analysis of threaded joints by the local approach are critically examined. The parallel development of a simplified experimental test system involving a threaded hole in cast AlSi7 is described and used to generate baseline fatigue data under known loading conditions. The fatigue behavior of the experimental system is then analyzed on the basis of alternate FE models and post processing approaches. Finally, recommendations for the accurate and computationally efficient FE modeling and durability analysis of threaded connections in cast aluminum cylinder block are outlined.
Speakers
Marco Bersella, Engineer, TP Engineering srl
With a wide range of applications varying from white goods, automotive, and aerospace applications, sheet metals are often high in strength relative to their cross section area. It’s important to note that formability and ductility is also crucial, for which the common testing requirements are similar across applications. Explore the challenges in sheet metal testing.
Composite Plate Optimization with Practical Design ConstraintsAltair
Composite free size optimization has the potential to generate weight savings and performance improvements for many applications of composite structures. Key to realizing such improvements is practical application of design and manufacturing constraints in the optimization model.
1. Effect of Sparse-build Internal Structure
on the Performance of Fused Deposition
Modeling Parts
SHIXUAN MENG
GRADUATE COMMITTEES MEMBERS:
Dr. MING C. LEU
Dr. K CHANDRASHEKHARA
Dr. HAILUNG TSAI
2. Objectives
• Investigate the effect of pressure environment on deformation,
stiffness for different internal structure of an autoclave molding tool
• Compare finite element analysis and experiment results to validate
the accuracy of SolidWorks FEA simulation solver
• Predict model performance in pressurized environment after the
FEA solver accuracy is proved
3. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
4. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
5. Background
• 0 - 0.689 MPa (0-100 psi)
• 25 – 177 oC (77-350 F)
3. After elevated temperature curing
cycle, resin is harden and part is ready
to use
1. Soft composite
fabric and uncured
resin are placed on
the mold
2. A vacuum is
used to keep the
composite fabric
and resin close to
the molding tool
6. Fused Deposition Modeling
1. CAD 2. Slice and generate toolpath
3. Fabrication 4. Finished part
• Three Top Cap Layers
• One Contour Layer with Internal Structure
• Three Bottom Cap Layers
Build
material
Support
material
Liquefier
Extrusion tip
Feed
motor
X
Z
7. Stratasys Fortus 400mc
• Accuracy: +/-.127mm or Up to +/- .0381 per mm
Tip cleaning station
Dual extrusion print head
(Build, support)
Heated chamber
Vacuumed print bed
Model material canister
Support material canister
40.6cm
35.6cm
8. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
9. Validation Model Optimization (mm)
Radius: 263.12
Radius: 263.12
A partial pressure testing tool is designed based on autoclave molding tool and
make it possible to experimentally verified the effectiveness of this method
Base load
head
Pressure
Top load
head
10. Design of Sparse Double Dense
Pattern
1 Contour @ 0.6604 mm (0.026 in)
Y-axis
X-axis
Raster width
@ 0.6096 mm
(0.024 in)
Raster angle
45 degree
SDD only
11. Topology Optimization
• Topology optimization is an effective methods to reduce weight while reduce the maximum
von Mises stress
• This method filter out mesh that has the lowest von Mises stress until objective is met after
FEA
• Possible objectives are: Volume constraint, maximum displacement constraint, or factor of
safety constraint
von
Mises
stress
12. Validation Model Topology Optimization
1. Initial model
2. Define boundary
conditions and design space
6. Finite element validation
3. Filter out the lowest local
Von Mises stress nodes until
requirement is met
4. Finalize topology optimization
to match material usage to
sparse double dense
5. Smoothing and generation
of FEA validation file
?
13. Redesign Based on Topology
Optimization
• Since length is fixed, width is adjusted to make volume identical to sparse double dense
• Redesigned geometry is generated with the help of probe coordination trend lines
• Build time reduced from 92 minutes to 73 minutes, maximum displacement was improved by
4.1 % according to FEA, Maximum von Mises is reduced by 2.3% due to force concentration
improvement
• Better appearance where interior is visible
Raw
topology
optimization
Redesign
based on
raw TO
model
Redesign
?
15. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
16. SolidWorks FEA Validation
Rigid load head
1 degree of freedom in
Z direction
Rigid fix bottom
load head
Evenly distributed pressure field on load head
Maximum displacement @ 30 MPa
(mm)
Maximum von Mises Stress @ 30 MPa
(MPa)
Solid 2.19E-01 14.651
Sparse double dense 2.67E-01 59.136
Topology optimization 2.24E-01 18.064
X-axis
Z-axis
17. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
18. Partial Pressure Experiment Results
Solid
Sparse Double Dense
Topology Optimization
• Since tolerances during fabrication, and
measurement exists, the displacement
point starts slightly different for each
part
• Linear data is needed to make results
more comparative
Displacement (mm)
Pressure(MPa)Pressure(MPa)Pressure(MPa)
Displacement (mm)
Displacement (mm)
Average slope of 5 linear portion
of solid compression test
New 0 for Strain and
Displacement
Pressure(MPa)
Displacement (mm)
19. Geometry Validation
Before compression
(mm)
After compression
(mm)
Percent difference
Average Width Height Width Height Width Height
Solid 76.42 9.20 76.50 9.15 0.09% -0.50%
Sparse double dense 76.42 9.25 76.43 9.23 0.00% -0.22%
Topology optimization 76.29 9.22 76.37 9.16 0.10% -0.66%
• A coordinate measuring machine is used
to measure the dimension before and
after partial pressure experiment
• A small plastic deformation occurred @
30 MPa, Therefore a smaller plastic
deformation is expected @ 0.689 MPa
• The results are based on the average
reading of 5 specimens
20. Partial Pressure Verification
The accuracy of the FEA solver is proved by the Partial Pressure Experiment
0
0.05
0.1
0.15
0.2
0.25
0.3
Solid SDD TO
FEA
Experiment
FEA displacement @ 30 MPa
Displacement(mm)
Maximum displacement (mm)
FEA Experiment Difference
Solid 0.219 0.2002 9.34%
SDD 0.267 0.2483 7.49%
TO 0.224 0.2114 5.92%
Percentage increased in maximum displacement
compare with Solid
FEA Experiment
SDD TO SDD TO
21.92% 2.28% 24.01% 5.58%
21. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
22. Full pressure Topology Optimization
1. TO result with low mesh density
Max. Disp.: 0.73 mm
3. Medium mesh density
Max. Disp.: 0.18 mm
5. High mesh density
Max. Disp.: 0.046 mm
4. Mid-high mesh density
Max. Disp.: 0.05 mm
?
6. Numerical analysis
2. Mid-low mesh density
Max. Disp.: 0.25 mm
Topology optimization study with different mesh size shows mesh
size dependency, therefore a numerical study is needed to find out
all possibilities
Maximum deformation
23. • Redesign was done imitating the raw
topology optimization and considered the
manufacturability
• FEA is studied using different numbers of
stiffener
• The higher number of stiffener does not
necessary mean improvement in
performance
• In this case 10 Stiffeners is the optimal
design
5 stiffeners 10 stiffeners
15 stiffeners 20 stiffeners
Topology Optimization Numerical Study
0
5
10
15
20
0 5 10 15 20 25
Maximum von Mises stress with
different number of stiffners
MaximumVonMisesstress(MPa)
Number of stiffners
0
0.01
0.02
0.03
0.04
0.05
0 5 10 15 20 25
Maximum displacement with
different number of stiffners
Maximumdisplacement(mm)
Number of stiffners
24. FEA Resultant Displacement @
.689476 MPa
• In autoclave full pressure
environment the displacement
difference is more significant
• Although sparse double dense
has less displacement, topology
optimization has a higher safety
factor
27. Dimples Close Look
• Dimples occurs in the center of air
gap due to the lack of support
behind the shell
• The deformation is maximized at the
edge where lack of horizontal and
vertical direction support
29. Full size model local deformation
Maximum z-direction local deformation= B – A
= -0.00533 – (-0.00420)
= -0.00113 mm
A B
SDD
TO
Maximum z-direction local deformation= B – A
= -0.00576 – (-0.00361)
= -0.00215 mm
A B
Y-axis
Z-axis
Y-axis
Z-axis
30. Outline
• Introduction
Background
• Validation model optimization
Model specification
Design of sparse double dense pattern
Topology Optimization
o Volume constraint topology optimization
o Improved Design
• Finite element analysis with partial pressure
• Experimental validate with partial pressure
Test results
Experiment verification
• Full pressure model optimization and finite element analysis
Topology optimization
Finite element
• Result and Conclusion
31. Partial Pressure FEA Comparison
• Topology optimization has a
small displacement that is
close to solid built
• Sparse double dense is the
fastest internal structure to
build for the same amount
of material
• If stiffness and material
usage are the main concern,
topology optimization is the
best internal structure for
compression application
32. Full Pressure FEA Comparison
• At 25oC (77 F), solid has the
best mechanical performance
• Sparse double dense is the
fastest internal structure to
fabricate in three designs, it
has a 3.3% less maximum
displacement compare to
redesigned topology
optimization.
• Redesigned topology
optimization offers 35.5% less
maximum Von Mises stress
than sparse double dense.
33. Conclusions
In the partial pressure FEA model @ 30MPa:
• Design with sparse double dense internal structure has 21.92% higher maximum
displacement compare to solid.
• Redesigned topology optimization only has 2.38% higher.
• In the partial pressure experiment @ 30 MPa:
• Parts with sparse double dense internal structure have an average of 24.01% higher
maximum displacement compare to solid.
• Redesigned topology optimization parts only have an average of 5.58% higher.
In the full pressure FEA model @ 0.689 MPa:
• Redesign topology optimization model has 26.25% higher maximum displacement compare
to design with sparse double dense internal structure and 981.08% higher maximum
displacement compare to solid design.
• Design with sparse double dense internal structure has a maximum von Mises stress that is
87.71% higher than Redesign topology optimization, and 7784% compare to solid.
• In partial pressure FEA model, the build time of redesigned topology optimization is 53%
longer than solid, and 102% longer than model with sparse double dense internal structure.
• In full pressure FEA model, the build time of redesigned topology optimization is 131%
longer than solid, and 217% longer than model with sparse double dense internal structure.
34. The Fortus 400mc machine successfully manufactured all testing tools with a tolerance between -0.17% and +0.5%; the testing tools are fabricated
with ULTEM 9085 material to validate the mechanical properties with FEA study results. The performance differences between the FEA solver and
experimentation are from 5.92% to 9.34%. The accuracy of the solver has been proven with different internal structure through validation process,
therefore the predictions of the parts’ performance are made for a full pressure environment at room temperature.
In the partial pressure FEA model at 30MPa:
The sparse double dense internal structure has an average of 21.92% higher maximum displacement compared to the solid internal structure.
The redesigned topology optimization has an average of 2.38% higher maximum displacement compared to the solid internal structure.
In the partial pressure experiment at 30 MPa:
The sparse double dense internal structure has an average of 24.01% higher maximum displacement compared to the solid internal structure.
The redesigned topology optimization has an average of 5.58% higher maximum displacement compared to the solid internal structure.
In the full pressure FEA model at 0.689 MPa:
The redesigned topology optimized internal structure has a 32.20% higher maximum displacement compared to the sparse double dense internal
structure and 905.40% higher maximum displacement compared to the solid internal structure.
The sparse double dense internal structure has a maximum von Mises stress that is 21.89% higher than the redesigned topology optimized
internal structure, and 501.33% higher von Mises stress than the solid internal structure.
Fabrication performance is predicted using Stratasys Insight 10.2. Since topology optimization software does not include designing for additive
manufacturing, the build time and amount of support material are larger than the sparse double dense internal structure. Even though the
redesigned topology optimization uses the same amount of build material as the sparse double dense internal structure, the build time is much
longer among different designs.
In the full pressure FEA model, the build time of the redesigned topology optimization is 53% longer than the solid internal structure, and 102%
longer than the sparse double dense internal structure.
In the full pressure FEA model, the build time of the redesigned topology optimization is 131% longer than the solid internal structure, and 217%
longer than the sparse double dense internal structure.
35. Reference
[1] Chua C. K., Leong K. F. and LIM C. S., "Rapid prototyping: Principles and Applications," Vol. 1, page 124-129
[2] Stratasys: http://usglobalimages.stratasys.com/Main/Files/Best%20Practices_BP/BP_FDM_VariableDensity.pdf?v=635817995040925513,
2015
[3] O. Iyibilgin, M. C. Leu, G. Taylor, H. Li, and K. Chandrashekhara, " Investigation of Sparse-Build Rapid Tooling by Fused Deposition
Modeling," Solid Freeform Fabrication Symposium, 2014
[4] Philip A. Browne, "Topology Optimization of Linear Elastic Structures," University of Bath Department of Mathematical Sciences, 2013
[5] INSTRON: http://www.instron.us/en-us/our-company/library/glossary/c/compression-test, 2015
[6] Adhiyamaan Arivazhagan, S.H. Masood, “Dynamic Mechanical Properties of ABS Material Processed by Fused Deposition Modeling, 2012
[7] INSPIRE SolidThinking:
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