4_2022_sen_8

Title of the article METHODOLOGICAL RECOMMENDATIONS ON TOPOLOGICAL OPTIMIZATION OF POWER STRUCTURES USING NUMERICAL MODELING TOOLS
Authors

IVCHENKO Vadim I., Deputy Head of the Republican Computer Center of Mechanical Engineering, Joint Institute of Mechanical Engineering of the NAS of Belarus, Minsk, Republic of Belarus, This email address is being protected from spambots. You need JavaScript enabled to view it.">This email address is being protected from spambots. You need JavaScript enabled to view it.

SHMIALIOU Aliaksei V., Ph. D. in Eng., Deputy Director General for Research, Joint Institute of Mechanical Engineering of the NAS of Belarus, Minsk, Republic of Belarus, This email address is being protected from spambots. You need JavaScript enabled to view it.">This email address is being protected from spambots. You need JavaScript enabled to view it.

TALALUEV Aleksey V., Head of the Republican Computer Center of Mechanical Engineering, Joint Institute of Mechanical Engineering of the NAS of Belarus, Minsk, Republic of Belarus, This email address is being protected from spambots. You need JavaScript enabled to view it.">This email address is being protected from spambots. You need JavaScript enabled to view it.

OMELIUSIK Aleksey V., Junior Researcher of the Republican Computer Center of Mechanical Engineering, Joint Institute of Mechanical Engineering of the NAS of Belarus, Minsk, Republic of Belarus, This email address is being protected from spambots. You need JavaScript enabled to view it.">This email address is being protected from spambots. You need JavaScript enabled to view it.
In the section COMPUTER MECHANICS
Year 2022
Issue 4(61)
Pages 68–79
Type of article RAR
Index UDK 004.942
DOI https://doi.org/10.46864/1995-0470-2022-4-61-68-79
Abstract Methodological recommendations are proposed for the development of the process of topological optimization of load carrying structures adapted for the use of additive technologies. The stage of postprocessing of the polygonal geometry of the part generated as a result of optimization is considered in detail. The validation stage is included in the process of topological optimization by comparing the calculated and experimental data to assess the operability (strength) of the optimized structure. For the option of manufacturing load carrying structures by 3D printing, it is planned to conduct studies of the mechanical properties of the material obtained on a 3D printer, taking into account the printing settings and the orientation of the material layers relative to the applied load during testing. An example of approbation of the proposed methodological recommendations is given on the example of a load carrying hook included in the design of a wheeled transport anti-ram device. The optimization was performed in the SolidThinking Inspire software environment (Altair Engineering, USA). The results of the calculated and experimental determination of the destructive load are presented for the initial and optimized hook design. For the experiment, the hooks were made of ABS plastic using FDM technology. Finite element models of hooks were developed in the ANSYS Workbench software package (ANSYS, USA). Assignment of material properties, boundary conditions and applied load is performed in the LS-PrePost application, calculation in the LS-DYNA solver (ANSYS, USA). The calculated and experimental efficiency estimates were 44.4 and 57.8 %, i.e. their difference is within 13.4 %. The zones and the nature of the destruction identified by calculation and experimentally completely coincide. The results obtained confirm the correctness of the proposed methodological recommendations, the selected modeling approaches and the determination of the properties of the material of the structure manufactured by 3D printing.
Keywords computer-aided design, modeling, topological optimization, methodology, power structure, weight reduction, stiffness increase, strength, ABS plastic, 3D printing, FDM technology
  You can access full text version of the article.
Bibliography
  1. Cazacu R., Grama L. Overview of structural topology optimization methods for plane and solid structures. Annals of the University of Oradea. Fascicle of management and technological engineering, 2014, vol. XXIII (XIII), iss. 3. DOI: 2014/3.10.15660/AUOFMTE.2014-3.3043.
  2. Sigmund O., Maute K. Topology optimization approaches: a comparative review. Structural and multidisciplinary optimization, 2013, vol. 48, iss. 6, pp. 1031–1055. DOI: https://doi.org/10.1007/s00158-013-0978-6.
  3. Zhu J.-H., Hou J., Zhang W.-H., Li Y. Structural topology optimization with constraints on multi-fastener joint loads. Structural and multidisciplinary optimization, 2014, vol. 50, iss. 4, pp. 561–571. DOI: https://doi.org/10.1007/s00158-014-1071-5.
  4. Leiva J.P. Structural optimization methods and techniques to design efficient car bodies. Proceedings of International automotive body congress 2011. Troy, MI, 2011, vol. 28, pp. 41–54. Available at: https://www.vrand.com/wp-content/uploads/2012/02/jpleiva_iabc2011.pdf (accessed 09 September 2022).
  5. Zhu J.-H., Zhang W.-H., Xia L. Topology optimization in aircraft and aerospace structures design. Archives of computational methods in engineering, 2016, vol. 23, iss. 4, pp. 595–622. DOI: https://doi.org/10.1007/s11831-015-9151-2.
  6. Brackett D., Ashcroft I., Hague R. Topology optimization for additive manufacturing. 22nd Annual international solid freeform fabrication symposium — An additive manufacturing conference, SFF. Austin, 2011, pp. 348–362.
  7. Tomlin M., Meyer J. Topology optimization of an additive layer manufactured (ALM) aerospace part. Proceeding of the 7th Altair CAE technology conference. 2011, pp. 1–9.
  8. Myagkov L.L., Chirskiy S.P. Realizatsiya topologicheskoy optimizatsii metodom BESO v srede ANSYS APDL i ee primenenie dlya optimizatsii formy shatuna teplovoznogo dizelya [The implementation of the BESO method for topology optimization in ANSYS APDL and its application for optimization of the connecting rod shape of a locomotive diesel engine]. BMSTU journal of mechanical engineering, 2018, no. 11(704), pp. 38–48. DOI: https://doi.org/10.18698/0536-1044-2018-11-38-48 (in Russ.).
  9. Popova D.D., Samoylenko N.A., Semenov S.V., Balakirev A.A., Golovkin A.Yu. Primenenie metoda topologicheskoy optimizatsii dlya umensheniya massy konstruktivno podobnogo kronshteyna truboprovoda aviatsionnogo GTD [Application of the topological optimization method to reduce the mass of gas turbine engine model bracket]. PNRPU aerospace engineering bulletin, 2018, no. 55, pp. 42–51. DOI: https://doi.org/10.15593/2224-9982/2018.55.05 (in Russ.).
  10. Hitrin A.M., Erofeeva M.M., Tuktamyshev V.R., Shiryaev A.A. Topologicheskaya optimizatsiya korpusnykh detaley vertoletnogo reduktora [Topological optimization of helicopter gearbox detail parts]. PNRPU aerospace engineering bulletin, 2018, no. 53, pp. 43–51. DOI: https://doi.org/10.15593/2224-9982/2018.53.04 (in Russ.).
  11. Poddubko S.N., Shmelev A.V., Ivchenko V.I., Zabolotskiy M.M., Trukhnov L.I., Khatskevich A.S. Kompyuternoe proektirovanie nesushchikh konstruktsiy mashin s primeneniem sredstv topologicheskoy
    optimizatsii [Computer-aided design of machines load-bearing structures using topology optimization tools]. Aktualnye voprosy mashinovedeniya, 2016, iss. 5, pp. 86–90 (in Russ.).
  12. Somireddy M., Czekanski A. Mechanical characterization of additively manufactured parts by FE modeling of mesostructure. Journal of manufacturing and materials processing, 2017, vol. 1, iss. 2. DOI: https://doi.org/10.3390/jmmp1020018.
  13. Bhandari S., Lopez-Anido R. Finite element modeling of 3D-printed part with cellular internal structure using homogenized properties. Progress in additive manufacturing, 2019, vol. 4, iss. 2, pp. 143–154. DOI: https://doi.org/10.1007/s40964-018-0070-2.
  14. Ferretti P., Santi G.M., Leon-Cardenas C., Fusari E., Donnici G., Frizziero L. Representative volume element (RVE) analysis for mechanical characterization of fused deposition modeled components. Polymers, 2021, vol. 13, iss. 20. DOI: https://doi.org/10.3390/polym13203555.
  15. Gonabadi H., Yadav A., Bull S.J. The effect of processing parameters on the mechanical characteristics of PLA produced by a 3D FFF printer. The international journal of advanced manufacturing technology, 2020, vol. 111, iss. 3–4, pp. 695–709. DOI: https://doi.org/10.1007/s00170-020-06138-4.
  16. Gonabadi H., Chen Y., Yadav A., Bull S. Investigation of the effect of raster angle, build orientation, and infill density on the elastic response of 3D printed parts using finite element microstructural modeling and homogenization techniques. The international journal of advanced manufacturing technology, 2022, vol. 118, iss. 5–6, pp. 1485–1510. DOI: https://doi.org/10.1007/s00170-021-07940-4.
  17. Maksimov P.V., Fetisov K.V. Analiz metodov dorabotki konechno-elementnoy modeli posle topologicheskoy optimizatsii [The analysis of methods of refinement of the finite element model after topology optimization]. International research journal, 2016, no. 9(51), pp. 58–60. DOI: https://doi.org/10.18454/IRJ.2016.51.102 (in Russ.).
  18. Optimize the shape of a part with the PolyNURBS tool in Inspire. Available at: https://www.sculpteo.com/en/tutorial/prepare- your-model-3d-printing-inspire/enhance-part-with-polynurbs- inspire/ (accessed 09 September 2022).
  19. Shmelev A.V., Ivchenko V.I., Talaluev A.V. Experimental and estimated determination of mechanical characteristics of 3D printed ABS plastic samples under tension. Engineering journal: science and innovation, 2021, no. 4(112). DOI: https://doi.org/10.18698/2308-6033-2021-4-2070.