APPLICATION OF TOPOLOGY OPTIMIZATION ON A 3D-PRINTED SHELF BRACKET

Year 2024, Volume: 8 Issue: 1, 32 - 45, 30.04.2024

Berker Özün Fenni , Ersin Eken , Hüseyin Kaygısız

https://doi.org/10.46519/ij3dptdi.1331696

Abstract

In this study, the topology optimization approach was adopted to reduce the material used in manufacturing. Specifically, the mass optimization technique was deemed suitable. Mass optimization eliminates the parts that don't affect a bracket’s overall strength while under load, resulting in weight reduction and material savings. Two shelf brackets were designed to test this theory and were subjected to mass optimization. A static structural analysis of this optimized model was carried out to confirm the optimization findings. These designs were then manufactured using the 3D-printing process. The yield points were next determined by performing a uniaxial tensile test on the shelf brackets. The outcome of the tests was subsequently compared with the simulation results, and a cost analysis model was created as an output. Ultimately, a reduction of 70% in mass was achieved with acceptable structural strength. In related optimization studies, the connecting part of an unmanned aerial vehicle's landing gear has been optimized resulting in fuel savings. The theory that topology optimization may be used to make both light and stiff parts at the same time has been proven by the results of this research as well as other studies that have been done on the same topic.

Keywords

Topology optimization, finite element analysis, 3D printing, CAD.

Supporting Institution

İstanbul Gedik Üniversitesi Gedik Meslek Yüksekokulu

Thanks

This study was carried out in the Istanbul Gedik University Vocational School 3D printing lab and the machine workshop with the assistance of Research Assistant Emre Tuğberk GÜLNERGİZ and Technician Ismail ÖRS.

References

• 1. Liu, S., Li, Q., Liu, J., Chen, W., Zhang, Y., ”A Realization Method for Transforming a Topology Optimization Design into Additive Manufacturing Structures”, Engineering, Vol. 4, Issue 2, Pages 277-285, 2018. 2.Brackett, D., Ashcroft, I., Hague, R., “Topology Optimization for Additive Manufacturing”, International Solid Freeform Fabrication Symposium, 348-362, Austin, Texas, 2011. 3. Moaveni, S., “Finite Element Analysis: Theory and Applications with ANSYS 4th Edition”, Pages 2-8, Pearson, USA, 2014. 4. MacNeal, R. H., "Some Organizational Aspects of NASTRAN”, Nuclear Engineering and Design, Vol. 29, Issue 2, Pages 254-265, 1974. 5. Ergin, A., Bayraktarkatal, E., Ünsan, Y., “Sonlu Elemanlar Metodu ve Gemi İnşaatı Sektöründeki Uygulamaları”, Türk Loydu Vakfı, 1-3, İstanbul, 2000.
• 6.Aslan, B., “Yenilikçi Tasarım Yöntemleri Kullanarak Eklemeli İmalata Yönelik Optimum Ürün Geliştirilmesi”, Yüksek Lisans Tezi, Bursa Teknik Üniversitesi, Bursa, 2019.
• 7.Vlah, D., Žavbi, R., Vukašinović, N., “Evaluations of Topology Optimization and Generative Design Tools as Support for Conceptual Design”, International Design Conference, Pages 451-460, Cambridge, 2020.
• 8.Ege, M., Küçük, S., “Energy Minimization of New Robotic-Type Above-Knee Prosthesis for Higher Battery Lifetime”, Applied Sciences, Vol. 13, Issue 6, Pages 3868, 2023.
• 9. Larsson, J., Wennhage, P., Göransson, P., “Mass Minimization with Conflicting Dynamic Constraints by Topology Optimization Using Sequential Integer Programming”, Finite Elements in Analysis and Design, Vol. 200, Pages 1-10, 2022.
• 10. Aktimur, B., Gökpınar, E., “Katmanlı Üretimin Havacılıktaki Uygulamaları”, Gazi University Journal of Science Part C: Design and Technology, Vol. 3, Issue 2, Pages 463-469, 2015. 11. Turhan, S., Özsoy, A., “DLMS Yöntemiyle İmal Edilen Ti6Al4V Alaşım Özelliklerine İşlem Parametrelerinin Etkisi”, Uluslararası Teknolojik Bilimler Dergisi, Vol. 8, Issue 2, Pages 15-27, 2016. 12. Frazier, W. E., “Metal Additive Manufacturing: A Review”, Journal of Materials Engineering and Performance, Vol. 23, Pages 1917-1928, 2014. 13.Wohlers, T., Gornet, T., “History of Additive Manufacturing”, Wohlers Report, Wohlers Associates, 2015.
• 14. Sidambe, A. T., “Biocompatibility of Advanced Manufactured Titanium Implants—A Review”, Materials, Vol. 7, Issue 12, Pages 8168-8188, 2014.
• 15.Hanon, M. M., Marczis, R., Zsidai, L., “Influence of the 3D Printing Process Settings on Tensile Strenght of PLA and HT-PLA”, Periodica Polytechnica Mechanical Engineering, Vol. 65, Issue 1, Pages 38-46, 2021.
• 16. Gonabadi, H., Yadav, A., Bull, S. J., “The Effect of Processing Parameters on the Mechanical Charasteristics of PLA Produced by a 3D FFF Printer”, The International Journal of Advanced Manufacturing Technology, Vol. 111, Issue 3-4, Pages 695-709, 2020.
• 17. Hibbeler, R. C., “Mechanics of Materials 8th Edition”, Pages 46-48, Pearson, USA, 2010.
• 18. Özsoy, K., Şentürk, E., Aydoğan, D., Korucu, Ö. E., “3B Yazıcı Teknolojisi için Topoloji Optimizasyonu: N95 Maske Üzerine Bir Çalışma”, Türk Doğa ve Fen Dergisi, Vol.. 9, Pages 152-159, 2020.
• 19.Çelebi, A., Tosun, H., “Application and Comparison of Topology Optimization for Additive Manufacturing and Machining Methods”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 5, Issue 3, Pages 676-691, 2021.
• 20. Koçak, M. R., Korkut, İ., “İnsansız Hava Aracı Burun İniş Takımı Çatalı için Topoloji Optimizasyonu Uygulaması”, Politeknik Dergisi, 1-1, 2022. 21. Top, N., Gökçe, H., Şahin, İ., “Eklemeli İmalat İçin Topoloji Optimizasyonu: El Freni Mekanizması Uygulaması”, Journal of Selcuk-Technic, Vol. 18, Issue 1, Pages 1-13, 2019.
• 22. Demir, N., Sucuoğlu, H. S., Böğrekci, İ., Demircioğlu, P., “Topology Optimization of Mobile Transportation Robot”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 5, Issue 2, Pages 210-219, 2021.
• 23. Dhinesh, S. K., Arun Prakash, S., Senthil Kumar, K. L., Megalingam, A., “Study on Flexural and Tensile Behavior of PLA, ABS and PLA-ABS Materials”, Materials Today: Proceedings, Vol. 45, Pages 1175-1180, 2021.
• 24.Porima 3D, “Porima PLA Filamentler”, https://static.ticimax.cloud/42373/uploads/dosyalar/porima-tds-tr.pdf, January 13, 2023.
• 25.Porima 3D, “Porima PLA Filamentler”, https://static.ticimax.cloud/42373/Uploads/Dosyalar/porima3d-e-katalog.pdf, January 13, 2023.
• 26. Ferreira, R., Amatte, I. C., Dutra, T. A., Bürger, D., “Experimental Characterization and Micrography of 3D Printed PLA and PLA Reinforced with Short Carbon Fibers, Composites”, Part B Engineering, Vol. 124, Issue 1, Pages 88-100, 2017.
• 27.Porima 3D, “Porima PLA Filamentler”, https://www.porima3d.com/porima-pla-filament, January 13, 2023.
• 28.Yıldız, A. R., “Taşıt Elemanlarının Yapısal Optimizasyon Teknikleri ile Optimum Tasarımı”, Politeknik Dergisi, Vol. 20, Issue 2, Pages 319-323, 2017.
• 29.Çağlayan, B. Ö., Ozakgül, K., Tezer, Ö., “Assessment of a Concrete Arch Bridge Using Static and Dynamic Load Tests”, Structural Engineering and Mechanics, Vol. 41, Issue 1, Pages 83-94, 2012.
• 30. Bell, D., Siegmund, T., “3D-printed polymers exhibit a strength size effect”, Additive Manufacturing, Vol. 21, Issue 1, Pages 658-665, 2018.