The information in this presentation is proprietary and confidential and shall not be disclosed to or

used by a third party unless specif ically authorised by the relevant GKN plc group company.

MSc. Thesis presentation

Topology-optimization-based model definition with manufacturing constraints

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Mariniello Emanuele I 12/06/2019

Supervisors Co-supervisor

Prof. Alberto Boschetto Ing. Timi Ojo Rus

Prof.ssa Luana Bottini

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Aim

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Presentation outline

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1. Introduction

- Additive Manufacturing

- Topology Optimization

2. Topology Optimization

- Methodology

- Outputs

3. Post Processing

- Methodology

- Outputs

- Comparison

4. Conclusions and Further works

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Additive Manufacturing

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The Additive Manufacturing processes are classified into 7 categories:

a) VAT Photopolymerization

b) Material Jetting

c) Binder Jetting

d) Material Extrusion

e) Powder Bed Fusion

f) Sheet Lamination

g) Directed Energy Deposition

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Topology Optimization

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It is a mathematical method that optimizes material with the typical goal of reduce the

mass of an object without compromise the mechanical resistance of its structure.

Solid Isotropic Material with Penalization (SIMP)

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Topology Optimization Software

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➢ Hyperworks

➢ Ansys

➢ Siemens NX

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Topology Optimization - Procedure

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1. Enough space to insert the pin in the lug;

2. Each interfaces between two consecutive sectors

needs to be flat;

3. Original flanges to maintain the seal condition and

design guidelines;

4. No application of “Air Force Method” normative.

Design Space constraints:

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Design Space and No Design Space

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Mechanical Loads

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Mechanical Loads

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Dummy

TRS

Load

Constraints

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Topology Optimization parameters

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Mindim: 7,5

Maxdim: 15

Stress Constraint: < 800 MPa

Volume fraction: 0,05

Objective function: minimize compliance

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0,505

TO Hyperworks Output

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Post Processing constraints

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1. The output of the TO has rough surface, it must be smoothed;

2. The connection between BHS and TRS must be closed;

3. Geometry on the bottom that allows to perform the liquid penetrate

inspection;

4. To reduce excessive use of support material, the structure needs to

have an overhang angle lower than 45 degrees, where it is possible.

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Post Processing “Concept 1” (No overhang angle constraints)

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Weight Reduction:

31 %

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Post Processing “Concept 2” (with overhang angle constraints)

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Post Processing “Concept 2” (with overhang angle constraints)

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Weight Reduction:

28 %

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“Concept 1” vs “Concept 2”

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Concept 1 Concept 2

OTM

Displacement AnalysisOriginal

≈ 4 mm

≈ 3,8 mm

≈ 6 mm

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“Concept 1” vs “Concept 2”

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FBO Tension

Stress Analysis

Concept 1

Concept 2

Max ≈ 1000 MPa

Max ≈ 780 MPa

Max ≈ 750 MPa

Original

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Post Processing “Concept 3” (Trade off)

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Weight Reduction:

25 %

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“Original” vs “Concept 3” – Stiffness X

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Original Concept 3

≈ 3,8 mm ≈ 4,2 mm

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“Original” vs “Concept 3” – FBO Tension

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Original Concept 3

Max ≈ 750 MPa Max ≈ 1100 Mpa

(locally)

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Conclusion

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• Weight reduction of 25%

• Reduction of support area of 13%

• More investigations about stresses

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Further Works

Presentation title 23

1. Topology Optimization implementing of the thermal stresses, drag

forces, fatigue and unexpected loads on the TRS;

2. Performing the Topology Optimization at more sectors at the same

time because each sector has different stresses;

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Thanks for the attention