基于对流-扩散方程的含自支撑内部孔结构拓扑优化
TOPOLOGY OPTIMIZATION WITH SELF-SUPPORTED ENCLOSED-VOIDS THROUGH ADVECTION-DIFFUSION EQUATIONS
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摘要: 在复杂结构的增材制造过程中, 加工悬空角小于特定临界值的表面通常需要添加辅助支撑. 辅助支撑的加工会导致材料浪费和制造成本上升, 包含于内部孔里面的辅助支撑更是难以移除. 本文提出了一种基于对流-扩散方程的自支撑内部孔设计方法, 能够在结构拓扑优化中只控制内部孔悬空角而不影响外部边界, 从而在消除内部辅助支撑的同时尽量减少结构性能损失. 在变密度拓扑优化中, 由于缺乏结构边界的显式描述, 从而难以识别内部孔并量化和控制悬空角. 本文利用对流-扩散方程模拟沿打印方向的光照过程, 能够识别光照下的阴影区域作为刀具不可达区域, 进而结合密度梯度构建了内部孔悬空角的全局约束. 此外, 为了保证识别得到的刀具不可达区域不包含外部悬垂面, 本文结合密度过滤和阶跃函数映射对中间拓扑构型进行了侵蚀, 能够有效避免对外部悬垂面的影响. 通过算例验证了所提出方法在包含自支撑内部孔结构拓扑优化方面的有效性, 并探讨了控制参数对优化结果的影响, 为结合拓扑优化和增材制造开展复杂结构一体化设计与加工提供了支撑.Abstract: In the additive manufacturing of structures with complex geometry, the auxiliary supports are generally required to fabricate surfaces with overhang angle smaller than the prescribed threshold. The fabrication of the support structures can lead to the increase of material waste and manufacturing cost. The support structures put on the enclosed voids are even difficult to remove after build. To solve this issue, this paper proposes an advection-diffusion equation based on topology optimization approach for designing self-supported enclosed voids. It can control the overhang angle of the enclosed voids in topology optimization without affecting the external surfaces. As a result, the internal support structures put on the enclosed voids can be eliminated without significant sacrifice of the structural performance. In the density-based topology optimization, due to the lack of explicit boundary representation, it is challenging to identify the enclosed voids and control their overhang angle. In this paper, by simulating the transport of light along the build direction through the advection-diffusion equation, we can identify the shadowed region as the inaccessible regions for machining tools. Combined with the spatial gradient of the density field, a global constraint is constructed to constrain the overhang angle of the enclosed voids in topology optimization. In addition, in order to exclude the external overhang boundaries from the inaccessible regions for machining tools, the intermediate density fields are eroded through the PDE-based density filtering and the Heaviside projection. Numerical examples are presented to demonstrate the efficacy of the proposed topology optimization method in the design of self-supported enclosed voids. The proposed method would help to further combine topology optimization and additive manufacturing in the generative design and fabrication of complex structures.