Thermal fatigue design of additive manufactured metal parts with lattice structures using selective laser melting method

• Κύριος συγγραφέας: Καλύβα, Δέσποινα
• Άλλοι συγγραφείς: Kalyva, Despoina
• Γλώσσα: English
• Έκδοση: 2023
• Θέματα: Additive manufacturing; Lattice structure; Lattice optimization; Thermo-mechanical analysis; Fatigue; Topology optimization; Προσθετική μηχανική; Δομή πλέγματος; Βελτιστοποίηση δομής πλέγματος; Θερμομηχανική ανάλυση; Κόπωση; Τοπολογική βελτιστοποίηση

Additive manufacturing is increasingly used as a primary way of creating components in multiple industries from aerospace and automotive, to bio-engineering, architecture and several more, due to its great advantages. For example, lightweighted parts, environmentally friendly production, lower cost, rapid production and so much more. The definition of AM given by the American Society for Testing and Material (ASTM) is as follows. “Additive manufacturing is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”. The additive manufacturing methods following this process are being presented as well as their applications. The main goal of the current research is to simulate an additive manufactured model and to compare it with a traditional made one. First, a simple geometry is simulated, a cantilever cylindrical beam. For the additive model, solid material is replaced by an infill of lattice structure. Lattice structures are considered a way to reduce weight while maintaining the required properties. Extra attention is needed in the way of shaping them to avoid high stress, deformation, strain or overhanging areas. Multiple types are being presented and tested through simulation concerning their performance under load. Following that, lattice optimization takes place for the beam and better values ensue, resulting in it being a more preferable method to simulate the additive manufactured beam. Afterwards, based on the results from the beam, a more compound geometry, a piston, is simulated with the same way, but examined for fatigue failure under thermo-mechanical loads. Finally, the results of the original geometry and the additive manufactured one are compared and discussed.