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An identification method for enclosed voids restriction in manufacturability design for additive manufacturing

Shutian LIU,Quhao LI,Wenjiong CHEN,Liyong TONG,Gengdong CHENG

《机械工程前沿（英文）》 2015年第10卷第2期页码 126-137 doi: 10.1007/s11465-015-0340-3

摘要：

Additive manufacturing (AM) technologies, such as selective laser sintering (SLS) and fused deposition modeling (FDM), have become the powerful tools for direct manufacturing of complex parts. This breakthrough in manufacturing technology makes the fabrication of new geometrical features and multiple materials possible. Past researches on designs and design methods often focused on how to obtain desired functional performance of the structures or parts, specific manufacturing capabilities as well as manufacturing constraints of AM were neglected. However, the inherent constraints in AM processes should be taken into account in design process. In this paper, the enclosed voids, one type of manufacturing constraints of AM, are investigated. In mathematics, enclosed voids restriction expressed as the solid structure is simply-connected. We propose an equivalent description of simply-connected constraint for avoiding enclosed voids in structures, named as virtual temperature method (VTM). In this method, suppose that the voids in structure are filled with a virtual heating material with high heat conductivity and solid areas are filled with another virtual material with low heat conductivity. Once the enclosed voids exist in structure, the maximum temperature value of structure will be very high. Based upon this method, the simply-connected constraint is equivalent to maximum temperature constraint. And this method can be easily used to formulate the simply-connected constraint in topology optimization. The effectiveness of this description method is illustrated by several examples. Based upon topology optimization, an example of 3D cantilever beam is used to illustrate the trade-off between manufacturability and functionality. Moreover, the three optimized structures are fabricated by FDM technology to indicate further the necessity of considering the simply-connected constraint in design phase for AM.

关键词： additive manufacturing topology optimization manufacturability constraints design for additive manufacturing simply-connected constraint

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喷气发动机部件的增材设计与制造

韩品连

《工程（英文）》 2017年第3卷第5期页码 648-652 doi: 10.1016/J.ENG.2017.05.017

摘要：

喷气发动机部件的增材设计（AD）和增材制造（AM）将彻底改变传统的航空航天工业。增材设计的独特性开创了喷气发动机设计和制造的新方向，比如梯度材料和微观结构。工程师已经从传统方法和技术的诸多限制中解放出来。增材制造过程最重要的特征之一是其可以确保零件的一致性，因为它始于点，继而到线和层面，直至整个部件完成。设计和制造之间的协调是空气动力学、热力学、结构整合、传热、材料开发和加工等方面取得成功的关键。工程师必须改变设计零件的方式，因为他们要从传统的“减材”方法转移到“增材”的新方法来制造零件。增材设计与增材制造设计不一样。我们需要一种新方法和新工具来协助这种新的设计和制方式。本文详细讨论了增材设计与增材制造中的需求，以及如何解决当前的问题。

关键词：增材制造增材设计喷气发动机多孔结构

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Topology optimization based on reduction methods with applications to multiscale design and additivemanufacturing

Emmanuel TROMME, Atsushi KAWAMOTO, James K. GUEST

《机械工程前沿（英文）》 2020年第15卷第1期页码 151-165 doi: 10.1007/s11465-019-0564-8

摘要： Advanced manufacturing processes such as additive manufacturing offer now the capability to control material placement at unprecedented length scales and thereby dramatically open up the design space. This includes the considerations of new component topologies as well as the architecture of material within a topology offering new paths to creating lighter and more efficient structures. Topology optimization is an ideal tool for navigating this multiscale design problem and leveraging the capabilities of advanced manufacturing technologies. However, the resulting design problem is computationally challenging as very fine discretizations are needed to capture all micro-structural details. In this paper, a method based on reduction techniques is proposed to perform efficiently topology optimization at multiple scales. This method solves the design problem without length scale separation, i.e., without iterating between the two scales. Ergo, connectivity between space-varying micro-structures is naturally ensured. Several design problems for various types of micro-structural periodicity are performed to illustrate the method, including applications to infill patterns in additive manufacturing.

关键词： multiscale topology optimization micro-structure additive manufacturing reduction techniques substructuring static condensation super-element

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多功能结构设计与原位制造 Article

张岩, 张广玉, 乔菁, 李隆球

《工程（英文）》 2023年第28卷第9期页码 58-68 doi: 10.1016/j.eng.2022.11.009

摘要：

多功能结构（MFS）通过多种功能融合以实现优异的综合性能，然而传统的多功能结构设计和制造方法通常缺乏质量控制，并且单一结构内集成不同材料和器件时需使用复杂装备和多种工艺，无法满足新兴产业如航天工程对多功能结构的应用要求。采用“为了制造而设计”的思想，我们利用基于分层调控原理的优化设计模型，设计出了同时包含机械承载、电气、导热和辐射屏蔽多种功能的典型结构；并且开发了一种高温原位增材制造（AM）技术，可打印各种金属丝和碳纤维增强的高熔点聚醚醚酮（PEEK）复合材料。研究结果表明，所设计的多功能结构相比同尺寸聚醚醚酮树脂基板具有更低质量，而且刚度提升了21.5%；集成的电学器件在多功能结构超出弹性变形阶段后仍然正常工作；与聚醚醚酮基板相比，多功能结构中心热源区域下方的等效导热率提高了568.0%，辐射屏蔽性能增强了27.9%；最终，我们以多功能结构为基础，研制了模块化拼装的卫星模型。这项工作不仅为高性能设计和先进制造提供了一套系统方法，并为高端装备的功能拓展和性能提升提供了重要的应用前景。

关键词：增材制造多功能结构优化设计卫星聚醚醚酮

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力学超构材料的结构设计与增材制造研究进展 Review

卢晨曦, Mengting Hsieh, 黄志锋, 张驰, 林耀军, 沈强, 陈斐, 张联盟

《工程（英文）》 2022年第17卷第10期页码 44-63 doi: 10.1016/j.eng.2021.12.023

摘要：

力学超构材料可以被定义为一类结构材料，它前所未有的力学性能源自人工结构设计而非其组成材料。虽然宏观尺度和简单设计的结构可以通过传统的自上而下方式来制备，但许多不同尺度下的复杂设计仍然难以实现。增材制造（AM）的最新进展导致了许多新的超构材料理念的实现。AM方法能够制造具有高精度、极其复杂和高特征保真度的微尺度结构，使力学超构材料的快速发展成为可能，并大大降低了设计计算和实验验证周期。本文首先基于所需的力学性能详细地回顾了各种拓扑结构，包括刚度、强度和负泊松比超构材料，然后讨论了能够制造这些超构材料的AM技术。最后，我们讨论了目前面临的挑战，并提出了AM和力学超构材料的未来发展方向。

关键词：力学超构材料负泊松比材料结构设计增材制造

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Design and applications of morphing aircraft and their structures

《机械工程前沿（英文）》 2023年第18卷第3期 doi: 10.1007/s11465-023-0750-6

摘要： Morphing aircraft can adaptively regulate their aerodynamic layout to meet the demands of varying flight conditions, improve their aerodynamic efficiency, and reduce their energy consumption. The design and fabrication of high-performance, lightweight, and intelligent morphing structures have become a hot topic in advanced aircraft design. This paper discusses morphing aircraft development history, structural characteristics, existing applications, and future prospects. First, some conventional mechanical morphing aircraft are examined with focus on their morphing modes, mechanisms, advantages, and disadvantages. Second, the novel applications of several technologies for morphing unmanned aerial vehicles, including additive manufacturing for fabricating complex morphing structures, lattice technology for reducing structural weight, and multi-mode morphing combined with flexible skins and foldable structures, are summarized and categorized. Moreover, in consideration of the further development of active morphing aircraft, the paper reviews morphing structures driven by smart material actuators, such as shape memory alloy and macro-fiber composites, and analyzes their advantages and limitations. Third, the paper discusses multiple challenges, including flexible structures, flexible skins, and control systems, in the design of future morphing aircraft. Lastly, the development and application of morphing structures in the aerospace field are discussed to provide a reference for future research and engineering applications.

关键词： morphing aircraft additive manufacturing lattice structure smart material flexible structure flexible skin

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Manufacturing cost constrained topology optimization for additive manufacturing

Jikai LIU, Qian CHEN, Xuan LIANG, Albert C. TO

《机械工程前沿（英文）》 2019年第14卷第2期页码 213-221 doi: 10.1007/s11465-019-0536-z

摘要： This paper presents a manufacturing cost constrained topology optimization algorithm considering the laser powder bed additive manufacturing process. Topology optimization for additive manufacturing was recently extensively studied, and many related topics have been addressed. However, metal additive manufacturing is an expensive process, and the high manufacturing cost severely hinders the widespread use of this technology. Therefore, the proposed algorithm in this research would provide an opportunity to balance the manufacturing cost while pursuing the superior structural performance through topology optimization. Technically, the additive manufacturing cost model for laser powder bed-based process is established in this paper and real data is collected to support this model. Then, this cost model is transformed into a level set function-based expression, which is integrated into the level set topology optimization problem as a constraint. Therefore, by properly developing the sensitivity result, the metallic additive manufacturing part can be optimized with strictly constrained manufacturing cost. Effectiveness of the proposed algorithm is proved by numerical design examples.

关键词： topology optimization manufacturing cost additive manufacturing powder bed

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Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing

Jinghua XU, Hongsheng SHENG, Shuyou ZHANG, Jianrong TAN, Jinlian DENG

《机械工程前沿（英文）》 2021年第16卷第1期页码 133-150 doi: 10.1007/s11465-020-0610-6

摘要： Surface accuracy directly affects the surface quality and performance of mechanical parts. Circular hole, especially spatial non-planar hole set is the typical feature and working surface of mechanical parts. Compared with traditional machining methods, additive manufacturing (AM) technology can decrease the surface accuracy errors of circular holes during fabrication. However, an accuracy error may still exist on the surface of circular holes fabricated by AM due to the influence of staircase effect. This study proposes a surface accuracy optimization approach for mechanical parts with multiple circular holes for AM based on triangular fuzzy number (TFN). First, the feature lines on the manifold mesh are extracted using the dihedral angle method and normal tensor voting to detect the circular holes. Second, the optimal AM part build orientation is determined using the genetic algorithm to optimize the surface accuracy of the circular holes by minimizing the weighted volumetric error of the part. Third, the corresponding weights of the circular holes are calculated with the TFN analytic hierarchy process in accordance with the surface accuracy requirements. Lastly, an improved adaptive slicing algorithm is utilized to reduce the entire build time while maintaining the forming surface accuracy of the circular holes using digital twins via virtual printing. The effectiveness of the proposed approach is experimentally validated using two mechanical models.

关键词： surface accuracy optimization multiple circular holes additive manufacturing (AM) part build orientation triangular fuzzy number (TFN) digital twins

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增材制造（3D打印）发展趋势 Perspective

卢秉恒, 李涤尘, 田小永

《工程（英文）》 2015年第1卷第1期页码 85-89 doi: 10.15302/J-ENG-2015012

摘要：

增材制造又称为3D打印，在过去30年间取得了快速发展并展示出前所未有的发展潜力。同时，这项发展潜力巨大的技术对传统工业也产生了不可估量的影响。3D打印技术将会推动生产模式的变革，通过实现5个“任意”的工艺发展，将会为制造行业带来一个以定制化制造为特征的新时代。3D打印的技术进步及其与传统制造工艺的融合，将推动制造业在材料研发、产品设计、生产工艺等方面进一步创新发展。最终，3D打印技术将与等材制造、减材制造形成三足鼎立局面，共同分享整个社会的制造业价值。

关键词：增材制造 3D打印制造模式定制化制造创新设计

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Additive manufacturing: technology, applications and research needs

Nannan GUO, Ming C. LEU

《机械工程前沿（英文）》 2013年第8卷第3期页码 215-243 doi: 10.1007/s11465-013-0248-8

摘要：

Additive manufacturing (AM) technology has been researched and developed for more than 20 years. Rather than removing materials, AM processes make three-dimensional parts directly from CAD models by adding materials layer by layer, offering the beneficial ability to build parts with geometric and material complexities that could not be produced by subtractive manufacturing processes. Through intensive research over the past two decades, significant progress has been made in the development and commercialization of new and innovative AM processes, as well as numerous practical applications in aerospace, automotive, biomedical, energy and other fields. This paper reviews the main processes, materials and applications of the current AM technology and presents future research needs for this technology.

关键词： additive manufacturing (AM) AM processes AM materials AM applications

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增材制造专题引言

增材制造专题编委会

《工程（英文）》 2017年第3卷第5期 doi: 10.1016/J.ENG.2017.05.027

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一种将拓扑优化设计转化为增材制造结构的实现方法 Article

刘书田, 李取浩, 刘君欢, 陈文炯, 张永存

《工程（英文）》 2018年第4卷第2期页码 277-285 doi: 10.1016/j.eng.2017.09.002

摘要：

拓扑优化是一种用于确定最佳结构构型以获得所需性能的功能强大的设计方法。它已被广泛用于工程领域，如航空航天和汽车行业，以提高所设计结构的性能。然而，拓扑优化和工程应用之间仍然存在着一些明显阻碍拓扑优化应用的空白。其中一个空白是如何将拓扑结果（尤其是那些使用变密度框架获得的拓扑结果）解释为参数化计算机辅助设计（CAD）模型，以为随后进行的形状优化和制造创造条件。本文提出了一种将拓扑优化结果解释为适用于增材制造的STL 模型和参数化CAD 模型的新方法。在这个方法中，我们将首先提取拓扑优化结果的骨架，以确保可以保持原有形状，并使用滤波手段来获得更加光滑的边界。经过这一过程后，拓扑优化结果边界的节点分布更密集，这将为后续的曲线拟合提供便利。该方法基于均匀B 样条曲线的曲率和曲率导数，提出了一种自适应的B 样条拟合方法，以获得满足误差要求的含最少控制点的参数化CAD 模型。通过一个案例研究对所提出的方法进行了详细的描述，并通过另外两个示例证明了所提出方法的有效性和鲁棒性。

关键词：拓扑优化增材制造特征保持自适应拟合形状优化

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Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Xiaodong NIU, Surinder SINGH, Akhil GARG, Harpreet SINGH, Biranchi PANDA, Xiongbin PENG, Qiujuan ZHANG

《机械工程前沿（英文）》 2019年第14卷第3期页码 282-298 doi: 10.1007/s11465-019-0526-1

摘要： Rapid prototyping (RP) or layered manufacturing (LM) technologies have been extensively used to manufacture prototypes composed mainly of plastics, polymers, paper, and wax due to the short product development time and low costs of these technologies. However, such technologies, with the exception of selective laser melting and sintering, are not used to fabricate metallic products because of the resulting poor life, short cycle, poor surface finish, and low structural integrity of the fabricated parts. The properties endowed by these parts do not match those of functional parts. Therefore, extensive research has been conducted to develop new additive manufacturing (AM) technologies by extending existing RP technologies. Several AM technologies have been developed for the fabrication of metallic objects. These technologies utilize materials, such as Ni-, Al-, and Ti-based alloys and stainless steel powders, to fabricate high-quality functional components. The present work reviews the type of materials used in laser-based AM processes for the manufacture of metallic products. The advantages and disadvantages of processes and different materials are summarized, and future research directions are discussed in the final section. This review can help experts select the ideal type of process or technology for the manufacturing of elements composed of a given alloy or material (Ni, Ti, Al, Pb, and stainless steel).

关键词： direct metal deposition laser-based manufacturing rapid manufacturing selective laser melting additive manufacturing

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拓扑优化中采用增材制造填充构件的结构屈曲荷载提升设计 Artical

Anders Clausen, Niels Aage, Ole Sigmund

《工程（英文）》 2016年第2卷第2期页码 250-257 doi: 10.1016/J.ENG.2016.02.006

摘要：

增材制造可实现优质多功能构件所具有的高度复杂几何构型的制备。可以直接制备内含多孔填充的结构部件是其独有特征的一个例证。现有的设计方法还难以充分利用这一设计自由度，直接获得类似结构的设计。本文将展示涂层方法 (coating approach) 的拓扑优化方法来作为多孔填充构件的设计方法，所设计的构件具有显著改进的临界屈曲载荷，从而使得整体结构部件的稳定性增强。传统的柔顺性拓扑优化方法极少在数学模型中考虑构件的屈曲约束，稳定性要求通常要经过后续的校核与改进过程满足。这一后续过程往往只能获得次优设计。本文所展示的方法弥补了传统柔顺性拓扑优化模型中难以考虑构件屈曲约束的缺陷。利用涂层拓扑优化方法与传统柔顺性拓扑优化同时对经典的MBB 梁进行设计，并采用熔丝增材制造技术对设计结果进行了制备。实验结果验证了涂层方法的数学模型的正确性。由于填充材料的性质，在相同条件下，涂层优化得到的多孔填充结构的屈曲载荷比传统优化得到的实体结构高四倍以上。

关键词：增材制造填充构件拓扑优化屈曲

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我国增材制造技术与产业发展研究

王磊,卢秉恒

《中国工程科学》 2022年第24卷第4期页码 202-211 doi: 10.15302/J-SSCAE-2022.04.018

摘要： Additive manufacturing of structural materials [J].Challenges in the technology development for additive manufacturing in space [J].Volumetric additive manufacturing of silica glass with microscale computed axial lithography [J].Hybrid metal additive manufacturing: A state-of-the-art review [J].Roadmap for additive manufacturing: Toward intellectualization and industrialization [J].

关键词：增材制造 3D打印先进制造高端装备产业复杂构件结构创新