Component-based Simultaneous Topology and Continuous Fiber Layout Optimization of Additively-manufactured Parts
Authors
Østergaard, Frederik Brun Hoff ; Larsen, Andreas Weje Warén
Term
4. term
Education
Publication year
2024
Submitted on
2024-05-31
Pages
91
Abstract
Denne afhandling undersøger, hvordan man samtidig kan optimere både topologi og kontinuerlig fiberlægning i additivt fremstillede, fiberforstærkede komponenter, så analysen stemmer overens med det, der kan produceres. Udgangspunktet er, at topologioptimering kan skabe komplekse, effektive geometrier, men at kommerciel fiberplacering ofte er intuitionsbaseret, og at mange optimeringsbaserede metoder kræver efterbehandling, som skaber et skel mellem analyse- og produktmodel. Arbejdet anvender Moving Morphable Components (MMC) med en ersatz-materialemodel, hvor hver komponent beskrives af en skeletkurve formuleret med Absolute Nodal Coordinate Formulation (ANCF). Herfra defineres fiberbaner og fremstillingsbegrænsninger, så fibre kan bevæge sig, bøjes og samles gennem designområdet. Målet er at minimere eftergivelighed (compliance) under en volumenbegrænsning, samtidig med at der håndhæves minimum fiberlængde, maksimal fiberkrumning og jævn fiberafstand i hver komponent. En overlappskonstraint forhindrer, at fibre placeres samme sted, og komponenters endepunkter kan sammenføres for at opnå kontinuitet på tværs af komponenter. Derudover indføres en styrkebetingelse via et Tsai–Wu-baseret fejlindeks. Resultaterne viser, at den foreslåede metode kan indbygge fremstillingsbarhed og sikre overensstemmelse mellem analyseret og produceret del; når kontinuitet opnås og alle betingelser overholdes, giver optimeringen designs med lav eftergivelighed, reduceret volumen, forventet sikkerhed mod svigt og et begrænset behov for efterbehandling. Afhandlingen afslutter med forslag til forbedringer af den numeriske model, komponentbeskrivelser og optimeringsformulering.
This thesis addresses how to simultaneously optimize topology and continuous fiber paths for additively manufactured, fiber‑reinforced parts in a way that preserves conformity between analysis and what can actually be produced. While topology optimization can yield efficient, complex shapes, commercial fiber placement is often intuition‑driven and many optimization approaches require post‑processing, creating a gap between analysis and product. The work employs the Moving Morphable Components (MMC) framework with an ersatz material model; each component is parameterized by a skeleton curve based on the Absolute Nodal Coordinate Formulation (ANCF), from which fiber paths and manufacturing constraints are defined, allowing fibers to move, curve, and merge across the design domain. The objective is to minimize compliance under a volume constraint, while enforcing a minimum fiber length, a maximum fiber curvature, and even intra‑component fiber spacing. An overlap constraint prevents fibers from occupying the same space, and component endpoints can merge to ensure inter‑component fiber continuity. A strength constraint using a Tsai–Wu failure index is also included. The results indicate that the proposed developments embed manufacturability and support conformity between the analyzed and produced part; when continuity is achieved and all constraints are satisfied, the scheme yields low‑compliance, volume‑reduced designs that are not expected to fail and can be produced with limited post‑processing. The thesis concludes with suggestions for improving the numerical model, component descriptions, and optimization formulation.
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