Anisotropic Effects on Topology Optimization for Additive Manufacturing in Aerospace Applications

Year 2025, Volume: 8 Issue: 1, 30 - 37, 31.05.2025

Onat Halis Totuk , Mustafa Özkara , Samet Akar

https://doi.org/10.34088/kojose.1565969

Abstract

This study investigates the effects of anisotropy on topology optimization in additive manufacturing, with a focus on aerospace applications. Topology optimization, a powerful design method for lightweight structures, is increasingly relevant in aerospace due to the adoption of additive manufacturing techniques. However, the anisotropic nature of materials used in these processes is often overlooked. This research compares isotropic and anisotropic analyses using TiAl4V and Epoxy Carbon UD Prepreg materials, examining stress distributions and optimization times. A cubic sample (40 mm) was subjected to various loading conditions, with a 10% mass retention constraint. Results demonstrate significant differences in stress levels and solution times between isotropic and anisotropic optimizations. For TiAl4V, the anisotropic analysis revealed notable variations in stress distribution and optimization times compared to isotropic assumptions. The composite material analysis further emphasized the importance of considering directional properties in optimization. Additionally, comparing aluminum and titanium components highlighted potential weight savings in certain applications. This study underscores the importance of incorporating anisotropic material properties in topology optimization for additive manufacturing, particularly in aerospace applications where weight reduction and structural integrity are critical. The findings suggest that anisotropic optimization could lead to more efficient designs and reduced computational times in specific loading scenarios.

Keywords

Anisotropic materials , Topology optimization , Additive manufacturing , Aerospace applications , Stress distribution

References

• [1] Zhu J., Zhou H., Wang C., Zhou L., Yuan S., Zhang W., 2020. A review of topology optimization for additive manufacturing: Status and challenges. Chinese Journal of Aeronautics, 34(1), pp. 91-110.
• [2] Ngo T., Kashani A., Imbalzano G., Nguyen K., Hui D., 2018. Additive manufacturing (3D printing): A review of materials, methods, applications and challenges. Composites Part B: Engineering, 143, pp. 172-196.
• [3] Liu S., Li Q., Liu J., Chen W., Zhang Y., 2018. A realization method for transforming a topology optimization design into additive manufacturing structures. Engineering, 4(2), pp. 277-285.
• [4] Zhu J.H., Zhang W.H., Xia L., 2016. Topology optimization in aircraft and aerospace structures design. Archives of Computational Methods in Engineering, 23(4), pp. 595-622.
• [5] Yiğitbaşi T.S., 2018. Mechanical properties of Ti6Al4V parts produced by electron beam melting and topology optimization in different building directions. Master’s Thesis, Middle East Technical University, Ankara.
• [6] Kılıç A.E., Savaş A., Yücesoy Y., 2024. Topology Optimization of Structural Drive-Train Component of an Electric-Driven Vehicle for Additive Manufacturing. Kocaeli Journal of Science and Engineering, 7(1), pp. 391-405.
• [7] Costa P., 2018. The History of Topology Optimization. [online] Available at: http://phelipecostapde.blogspot.com/2018/04/the-history-of-topology-optimisation.html [Accessed 10 April 2018].
• [8] Bendsøe M.P., Kikuchi N., 1988. Generating optimal topologies in structural design using a homogenization method. Computer Methods in Applied Mechanics and Engineering, 71(2), pp. 197-224.
• [9] Bendsøe M.P., 1989. Optimal shape design as a material distribution problem. Structural Optimization, 1(4), pp. 193-202.
• [10] Xie Y.M., Steven G.P., 1993. A simple evolutionary procedure for structural optimization. Computers & Structures, 49(5), pp. 885-896.
• [11] Querin O.M., Steven G.P., Xie Y.M., 1998. Evolutionary structural optimisation (ESO) using a bidirectional algorithm. Engineering Computations, 15(8), pp. 1031-1048.
• [12] Osher S., Sethian J.A., 1988. Fronts propagating with curvature-dependent speed: Algorithms based on Hamilton-Jacobi formulations. Journal of Computational Physics, 79(1), pp. 12-49.
• [13] Raise3D, 2023. 3D Printing History: A Complete Timeline of Additive Manufacturing Evolution. [online] Available at: https://www.raise3d.com/blog/3d-printing-history/ [Accessed 12 October 2024].
• [14] Wasti S., Adhikari S., 2020. Use of biomaterials for 3D printing by fused deposition modeling technique: A review. Frontiers in Chemistry, 8, p. 315.
• [15] Loughborough University, n.d. The 7 categories of Additive Manufacturing. [online] Available at: https://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/ [Accessed 12 October 2024].
• [16] Thomas Publishing Company, 2024. Additive Manufacturing in Aerospace: Advantages, Applications, and Challenges. [online] Available at: https://www.thomasnet.com/insights/additive-manufacturing-aerospace/ [Accessed 30 August 2024].
• [17] Formlabs, 2024. 9 Applications of 3D Printing in Aerospace. [online] Available at: https://formlabs.com/asia/blog/additive-manufacturing-3d-printing-in-aerospace/ [Accessed 10 October 2024].
• [18] Hubs, 2024. 3D printing for aerospace and aviation. [online] Available at: https://www.hubs.com/knowledge-base/aerospace-3d-printing-applications/ [Accessed 19 September 2024].
• [19] Avior Integrated Systems, 2024. The Important Role of Additive Manufacturing in Aerospace. [online] Available at: https://www.avior.ca/blog/role-of-additive-manufacturing-in-aerospace/ [Accessed 19 September 2024].
• [20] ANSYS, Inc., 2023. ANSYS Mechanical [Computer software]. Canonsburg, PA.
• [21] Bakis G., Wendel J.-F., Zeiler R., Aksit A., Häublein M., Demleitner M., Benra J., Forero S., Schütz W., Altstädt V., 2021. Mechanical Properties of the Carbon Nanotube Modified Epoxy–Carbon Fiber Unidirectional Prepreg Laminates. Polymers, 13(5), p. 770.
• [22] Kurkin E., Espinosa Barcenas O.U., Kishov E., Lukyanov O., 2024. Topology Optimization and Efficiency Evaluation of Short-Fiber-Reinforced Composite Structures Considering Anisotropy. Computation, 12(2), p. 35.
• [23] Continental Steel, 2015. Aluminum in the Aerospace Industry. [online] Available at: https://continentalsteel.com/blog/aluminum-in-the-aerospace-industry/ [Accessed 15 October 2015].