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See detailFatigue resistant designs using stress-based topology optimization
Collet, Maxime ULiege; Bauduin, Simon ULiege; Fernandez Sanchez, Eduardo Felipe ULiege et al

Conference (2017, September 15)

Fatigue is an important mode of failure in mechanical engineering and accounting for it as soon as the early stage of design using topology optimization sounds primordial. Structures undergoing high-cycle ... [more ▼]

Fatigue is an important mode of failure in mechanical engineering and accounting for it as soon as the early stage of design using topology optimization sounds primordial. Structures undergoing high-cycle fatigue can be described by the stress-based approach and then a stress-based topology optimization framework, which has received great interest since almost 20 years because of the innovative designs that can be achieved to answer strength requirements, can be used. Literature reports many good results for shape optimization [Mrzyglod & Zielinsky(2006)] whereas in the eld of topology optimization several authors have shown that considering fatigue in an optimization framework leads to more relevant solutions where fluctuating loads are involved [Holmberg E.(2015), Collet et al(2016), Sv ard(2015)]. The good behaviour of the implementation of an advanced fatigue criterion, i.e. the multiaxial Dang Van criterion [Dang Van et al(1989)] is first investigated in the framework of a density-based topology optimization problem. The choice of this fatigue criterion is justifed by its good applicability in automotive or aeronautic industry as well as its relevancy with respect to experimental results. We present the sensitivity analysis with stress constraints and present some classical benchmarks to illustrate the behaviour of the optimized solution. In a second time, the fatigue resistance is introduced in the well-known microstructural design [Sigmund (2000)] also know as architectured material design which are now considered in mechanical engineering because of their manufacturability thanks to additive manufacturing processes. Ensuring the fatigue resistance of the cellular material will by extension ensure the structural integrity of the overall structure itself. The optimization is performed by using the MMA optimizer [Svanberg(1987)] whereas the singularity phenomenon of the stress constraints is circumvented by using the qp-relaxation [Bruggi(2008)]. Both types of optimization framework are evaluated in term of their numerical performances and are compared to classical results generated by a regular stress-based topology optimization. Finally, the results are 3D-printed to assess for their manufacturability. [less ▲]

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See detailFatigue resistant designs using stress-based topology optimization
Collet, Maxime ULiege; Bauduin, Simon ULiege; Fernandez Sanchez, Eduardo Felipe ULiege et al

Conference (2017, June 08)

Stress based topology optimization has received great interest since almost 20 years because of the innovative designs that can be achieved to answer strength requirements. Fatigue is an important mode of ... [more ▼]

Stress based topology optimization has received great interest since almost 20 years because of the innovative designs that can be achieved to answer strength requirements. Fatigue is an important mode of failure in mechanical engineering and accounting for it as soon as the early stage of design using topology optimization sounds primordial. Literature reports many good results for shape optimization [Mrzyglod & Zielinsky(2006)] whereas in the field of topology optimization several authors have shown that considering fatigue in an optimization framework leads to more relevant solutions where fluctuating loads are involved [Holmberg E.(2015), Collet et al(2016), Svärd(2015)]. In order to check the good behavior of the implementation, we first investigate the implementation of an advanced fatigue criterion, i.e. the multiaxial Dang Van criterion [Dang Van et al(1989)], in the framework of a density-based topology optimization problem. The choice of this fatigue criterion is justifed by its good applicability in automotive or aeronautic industry as well as its relevancy with respect to experimental results. We present the sensitivity analysis with stress constraints and present some classical benchmarks to illustrate the behavior of the optimized solution. In a second time, we introduce the fatigue resistance in the well-known microstructural design [Sigmund (1999)]. The new additive manufacturing techniques allow to fabricate components exhibiting architectured materials. In this perspective, ensuring the fatigue resistance of the cellular material will by extension ensure the structural integrity of the overall structure itself. Both types of optimization framework are evaluated in term of their numerical performances and are compared to classical results generated by a regular stress-based topology optimization. Finally, the results are 3D-printed to assess for their manufacturability. [less ▲]

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See detailTopology optimization of mechanical components fabricated by additive manufacturing for a Shell Eco Marathon vehicle
Alarcon Soto, Pablo ULiege; Collet, Maxime ULiege; Bauduin, Simon ULiege et al

Conference (2017, June 07)

Since 2004, a team of students and researchers of University of Liege takes part to the Shell Eco Marathon race with a lightweight electric vehicle. The goal of this pedagogical project is to design ... [more ▼]

Since 2004, a team of students and researchers of University of Liege takes part to the Shell Eco Marathon race with a lightweight electric vehicle. The goal of this pedagogical project is to design, fabricate and operate a vehicle exhibiting the least energy consumption. A key factor to reduce the energy consumption is to minimize the vehicle mass. Besides the body structure made of CRFP, engineers have also to focus on the weight reduction of any mechanical parts of the powertrain, transmission and of rolling gear. The combination of topology optimization with additive manufacturing techniques allows to propose innovative designs exhibiting a high performance to weight ratio. Topology optimized designs are often characterized by a high geometrical complexity that is not possible to manufacture without 3D printing. This work presents the CAE design methodology that was developed to combine topology and shape optimization with 3d printing manufacturing. Novel developments both in shape and topology optimization have also been realized for the specific character of these components. The design methodology is illustrated with several applications of components of our new Eco Marathon prototype. They include a support for electric traction motors and different torque arms of the steering mechanism to be implemented in the new 2017 vehicle. The presentation is going to show the different design steps from the specifications and the formulation of the design problem to the 3D-printing of the parts: the topology optimization, interpretation and CAD reconstruction, shape optimization and detailed finite element verification of the solution. The optimization is performed thanks to the commercial software NX-TOPOL and the final CAD design is reconstructed in the CATIA environment software after a smoothing procedure in the NX-CAD environment. We show that the final design can be 3D-printed and a comparison with a design produced using traditional design approach is provided. [less ▲]

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See detailContributions to handle maximum size constraints in density-based topology optimization
Fernandez Sanchez, Eduardo Felipe ULiege; Collet, Maxime ULiege; Bauduin, Simon ULiege et al

in Fiebig, Sierk; Bletzinger, Kai-Uwe; Maute, Kurt (Eds.) et al Advances in Structural and Multidisciplinary Optimization (2017, June 05)

The maximum size formulation in topology optimization restricts the amount of material within a test region in each point in the design domain, leading to a highly constrained problem. In this work the ... [more ▼]

The maximum size formulation in topology optimization restricts the amount of material within a test region in each point in the design domain, leading to a highly constrained problem. In this work the local constraints are aggregated into a single one by p-mean and p-norm functions, classically used for stress constraints. Moreover, a new test region is investigated which is a ring instead of the classical circle around the element. These developments were implemented for compliance minimization with the MBB beam test case. Results indicate that p-mean performs better in the maximum size field than p-norm, because it underestimates the most violated constraint. This gives some relaxation to the problem that allows stiffer connections. Similar effect has been observed for the ring-shaped region which reduces the amount of holes that are introduced in the structure, specially in the connection of solid members. In addition, it is shown that the maximum size formulation allows the definition of the minimum gap between solid members which gives designers more control over the geometry. The developments have been illustrated and validated with compliance minimization tests of 2D-domains. [less ▲]

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