2,283 research outputs found

    Designing Volumetric Truss Structures

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    We present the first algorithm for designing volumetric Michell Trusses. Our method uses a parametrization approach to generate trusses made of structural elements aligned with the primary direction of an object's stress field. Such trusses exhibit high strength-to-weight ratios. We demonstrate the structural robustness of our designs via a posteriori physical simulation. We believe our algorithm serves as an important complement to existing structural optimization tools and as a novel standalone design tool itself

    Optimization and visualization of rapid prototyping process parameters.

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    The optimal selection of rapid prototyping (RP) process parameters is a great concern to RP designers. When dealing with this problem, different build objectives have to be taken into consideration. Using virtual rapid prototyping (VRP) systems as a visualization tool to verify the optimally selected process parameters will assist designers in taking critical decisions regarding modeling of prototypes. This will lead to substantial improvements in part accuracy using minimal number of iterations, and no physical fabrication until confident enough to do so. The purpose of this thesis is to demonstrate that virtual validation of optimally selected process parameters can significantly reduce time and effort spent on traditional RP experimentation. To achieve the goal of this thesis, a multi-objective optimization technique is proposed and a model is generated taking into consideration different build objectives, which are surface roughness, support structure volume, build time and dimensional accuracy. The multi-objective method used is the weighted sum method, where a single utility function has been formulated, which combines all the objective functions together. The orders of magnitudes have been normalized, and finally weights have been assigned for each objective function in order to create the general formulation. (Abstract shortened by UMI.)Dept. of Industrial and Manufacturing Systems Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2004 .E47. Source: Masters Abstracts International, Volume: 43-03, page: 0959. Adviser: Waguih ElMaraghy. Thesis (M.A.Sc.)--University of Windsor (Canada), 2004

    Designing heterogeneous porous tissue scaffolds for additive manufacturing processes

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    A novel tissue scaffold design technique has been proposed with controllable heterogeneous architecture design suitable for additive manufacturing processes. The proposed layer-based design uses a bi-layer pattern of radial and spiral layers consecutively to generate functionally gradient porosity, which follows the geometry of the scaffold. The proposed approach constructs the medial region from the medial axis of each corresponding layer, which represents the geometric internal feature or the spine. The radial layers of the scaffold are then generated by connecting the boundaries of the medial region and the layer's outer contour. To avoid the twisting of the internal channels, reorientation and relaxation techniques are introduced to establish the point matching of ruling lines. An optimization algorithm is developed to construct sub-regions from these ruling lines. Gradient porosity is changed between the medial region and the layer's outer contour. Iso-porosity regions are determined by dividing the subregions peripherally into pore cells and consecutive iso-porosity curves are generated using the isopoints from those pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, the generated contours are optimized for a continuous, interconnected, and smooth deposition path-planning. A continuous zig-zag pattern deposition path crossing through the medial region is used for the initial layer and a biarc fitted isoporosity curve is generated for the consecutive layer with C-1 continuity. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using additive manufacturing processes

    A review of geometry representation and processing methods for cartesian and multiaxial robot-based additive manufacturing

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    Nowadays, robot-based additive manufacturing (RBAM) is emerging as a potential solution to increase manufacturing flexibility. Such technology allows to change the orientation of the material deposition unit during printing, making it possible to fabricate complex parts with optimized material distribution. In this context, the representation of parts geometries and their subsequent processing become aspects of primary importance. In particular, part orientation, multiaxial deposition, slicing, and infill strategies must be properly evaluated so as to obtain satisfactory outputs and avoid printing failures. Some advanced features can be found in commercial slicing software (e.g., adaptive slicing, advanced path strategies, and non-planar slicing), although the procedure may result excessively constrained due to the limited number of available options. Several approaches and algorithms have been proposed for each phase and their combination must be determined accurately to achieve the best results. This paper reviews the state-of-the-art works addressing the primary methods for the representation of geometries and the subsequent geometry processing for RBAM. For each category, tools and software found in the literature and commercially available are discussed. Comparison tables are then reported to assist in the selection of the most appropriate approaches. The presented review can be helpful for designers, researchers and practitioners to identify possible future directions and open issues

    Optimal Placement of Metal Foils in Ultrasonic Consolidation Process

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    Ultrasonic Consolidation is a combination of additive and subtractive manufacturing processes resulting in considerable material waste. This waste is a function of the geometry of the part being manufactured and of the relative placement of the layer with respect to the metal bands. Thus the waste may be minimized by careful choice of the layer angle and offset from the original position. Previous work done in this field had developed an automated algorithm which optimally places and orients the individual slices of the STL file of the artifact being manufactured. However, the problem was solved on a 2-D scale and the 3- D nature of the part was not considered for the development of the algorithm. The earlier algorithm employed approximation on the input data to minimize the computational expense. This resulted in convergence of the optimizer to suboptimal solutions. Further, as the final part is made of anisotropic material the relative angles and overlap between subsequent layers also plays an important role in the final part strength. Finally, it is noted that the build time required for the ultrasonic consolidation process is a function of the number of bands required to form each slice. Considering these limitations and opportunities, this thesis presents an algorithm which optimally orients and places the part layers with respect to aluminum bands in order to minimize the waste formed and the build time required. The algorithm has the capability of increasing the part strength by forming crisscross and brick structures using the metal foils. This research work also improves on the previous algorithm by extending the functionality of the algorithm by building in capability to handle multiple loops within the same slice and non convex slice data. Further, the research studies the choice of optimizer that needs to be employed for different types of input data

    Addressing Thermal Distortion in Additive Manufacturing of Topology Optimized Structures Through Reverse Shape Morphing

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    Design of light weight structures is an important aspect in the aircraft industry, since minimizing the weightof components improves the overall aircraft performance. However, conventional manufacturing methods work on standard geometries and shapes, and often lead to overdesigning of parts. Additive Manufacturing (AM) overcomes these issues by allowing more design freedom. The present study focuses on two aspects of AM: (1) part consolidation through topology optimization, and (2) addressing thermal distortion through reverse shape morphing. An assembly of two load bearing brackets is first amalgamated into a single Topology Optimized (TO) part, which satisfies the displacement and stress requirements of the original design. After a series of optimization iterations, the final TO part (278 g) weighs 69 % lesser than the original assembled design (909 g), still meeting the design constraints. The TO part thus eliminates the need of fasteners to join both the brackets, thereby, making the design simpler yet effective. Moreover, a homogeneous stress distribution in the optimized part allows for efficient material utilization. In order to overcome thermal distortion that results during the AM process, the shape of the TO part is transformed in a sense opposite to the distortions produced. This is achieved through reverse shape morphing technique, that reduces thermal distortions in the printed part to sub-micron levels, and the morphed TO part conforms to the requirements meeting the design constraints. Therefore, the implementation of topology optimization along with reverse shape morphing makes the design simple and efficient having reduced distortion. This is achieved without any need of modifications in the manufacturing system or equipment, and such a strategy can be replicated and implemented at industrial scale as well

    Procedural function-based modelling of volumetric microstructures

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    We propose a new approach to modelling heterogeneous objects containing internal volumetric structures with size of details orders of magnitude smaller than the overall size of the object. The proposed function-based procedural representation provides compact, precise, and arbitrarily parameterised models of coherent microstructures, which can undergo blending, deformations, and other geometric operations, and can be directly rendered and fabricated without generating any auxiliary representations (such as polygonal meshes and voxel arrays). In particular, modelling of regular lattices and cellular microstructures as well as irregular porous media is discussed and illustrated. We also present a method to estimate parameters of the given model by fitting it to microstructure data obtained with magnetic resonance imaging and other measurements of natural and artificial objects. Examples of rendering and digital fabrication of microstructure models are presented
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