Shape optimization methods for additive manufacturing

• Κύριος συγγραφέας: Λιανός, Ανδρέας
• Άλλοι συγγραφείς: Σταυρόπουλος, Παναγιώτης
• Μορφή: Thesis
• Γλώσσα: English
• Έκδοση: 2019
• Θέματα: Additive manufacturing; Design; DfAM; Post-processing; Προσθετικές τεχνολογίες

Additive Manufacturing (AM) technologies are thought to be the next big thing in the industry, revolutionizing the manufacturing sector and changing the nature of how a physical product is realized. The advantageous nature of the AM technologies originates from the selective deposition of the material that morphs the part via multiple layers. That is, the AM layering nature is both benefit and constrain as it introduces manufacturability constrains. These buildability restrictions need to be thoroughly considered when engineering and designing an AM part in order to fully utilize the AM’s advantageous nature. This nature includes, but is not limited to, the manufacturing of highly complex components and assemblies with enhanced performance and added lightness. The AM capabilities of complex geometric structures and the tool-free flexibility in production of the AM machines can overperform the equivalent capabilities of the conventional manufacturing techniques. With these design possibilities the AM technologies are redefining the engineering of the part design, while shifting the design mindset away from the future based method towards a functioned based approach; the function of the desired part is used as input for the design and not as a final check, of will or will not endure/perform. To accomplish that and optimize the overall AM process a design methodology is proposed that addresses the buildability restrictions imposed by the different AM technologies. This AM design methodology defines the generic terms used within the AM academia and industry and further enhances them through the prism of design. This AM design framework can be the foundation stone of parameter optimization algorithms; as the constants, variables and outcomes of the geometrical AM design have been determined. The final chapter of this thesis is a novel shape optimization method. This part shaping method for AM is based on the previously developed design framework and addresses both topology and manufacturability goals. The part is shaped based on the developed stresses and the AM manufacturability restrictions, resulting in a design optimum in both worlds. AKL