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

点击翻译按钮获取中文摘要

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.