Function-driven design and simulation methods for hierarchical multi-material structures fabricated via additive manufacturing processes

加法制造是由美国测试材料协会定义的一种制造方法，通过添加材料来构建S 3D对象，通常是以一层到一层的方式。与其他制造方法相比，它们具有独特的优势，例如能够制造具有复杂形状的物体，这些物体由具有不同材料属性的不同材料制成。AM方法的能力极大地提高了设计师为各种新应用探索新的工程产品的自由度。事实上，AM技术通过创造具有成本效益的高价值产品，在制造业中创造了一个新的范例。然而，在早期设计阶段，还没有有效的设计方法来鼓励功能集成。此外，现有的几何建模方法，如参数边界表示或实体建模技术，为表示传统制造过程中相对简单的几何形状而开发，不再能够为AM设计表示足够的信息。迫切需要创新的设计方法和更好的计算机辅助设计工具来支持利用AM方法实现新产品。该研究计划旨在建立一个功能驱动的设计和仿真平台，能够设计、建模和仿真具有多材料分布的分层结构。为了实现所提出的平台，计划实现以下研究目标：1)开发面向AM的设计(DFAM)方法，以帮助设计人员定义和探索由AM支持的设计空间该方法侧重于概念设计和体现设计的第一步。利用信息建模技术为功能驱动型DFAM零件合并新方法建立AM知识支持；2)开发几何建模和优化方法和工具，支持具有不同材料分布的层次化复杂结构的设计。混合几何建模技术将被开发以支持快速的网格生成；3)开发基于实体和梁混合有限元的层次化复杂性和非均匀材料组成的新的模拟方法和工具。提出的研究方案旨在进行基础研究，以推进具有分层多尺度结构和多种材料组成的复杂对象的设计、建模和仿真。开发的方法和工具将帮助设计者在概念设计、详细设计和设计优化阶段充分利用添加剂制造技术提供的设计自由度。它提供了一种系统的方法和计算机辅助工具来设计在航空航天、汽车和医疗植入物/假体行业中广泛应用的创新产品。**

Additive Manufacturing (AM) is defined by the American Society of Testing Materials (ASTM) as a class of manufacturing methods to build s 3D objects by adding materials typically in a layer-upon-layer manner. They have unique advantages over other manufacturing methods such as the capability to fabricate objects with complex shapes, made of heterogeneous materials with varying material properties. The capability of AM methods greatly enhances freedom for designers to explore novel engineered products for a variety of new applications. In fact, AM technologies have created a new paradigm in manufacturing by enabling the creation of cost effective high value products. However, there is no valid design method to encourage function integration at early design stage. Moreover, existing geometric modeling methods, such as parametric boundary representation or solid modeling techniques developed to represent relatively simple geometries for conventional manufacturing processes, are no longer capable to represent sufficient information for AM design. There is an urgent need for innovative design methods and better computer-aided design tools to support the realization of novel products using AM methods.The proposed research program aims to establish a function-drive design and simulation platform that is capable of designing, modeling, and simulating hierarchical structures with multi-material distribution. To realize the proposed platform, the following research objectives are planned:1) Development of Design for AM (DfAM) methods to aid designers in defining and exploring design spaces enabled by AM. This method focuses on conceptual design and first steps of embodiment design. Information modeling technique will be used to establish AM knowledge support to the novel function-drive DfAM method for part consolidation; 2) Development of geometric modeling and optimization methods and tools to support the design of hierarchical complex structure with varied material distribution. Hybrid geometric modeling techniques will be developed to support fast lattice generation; 3) Development of novel simulation methods and tools for hierarchical complexity and heterogeneous material composition using solid and beam hybrid finite element method. The proposed research program aims at fundamental research to advance the design, modeling and simulation of complex objects with hierarchical multi-scale structure and varied material composition. The developed method and tools will aid designers in conceptual design, detailed design, and design optimization stages to take full advantage of the design freedom provided by additive manufacturing technology. It provides a systematic approach with computer-aided tools to design innovative products that have wide applications in aerospace, automobile, and medical implant/prosthetics industry. **