The lattice structure configuration design for stereolithography investment casting pattern using topology optimization

Purpose – The purpose of this paper is to introduce, for the first time, the topology optimization method into the lattice structure configuration design for rapid casting patterns.Design/methodology/approach – A structural topology optimization procedure in combination with thermo‐mechanical finite element analysis for the lattice structure configuration design has been developed.Findings – A new mixed stress‐compliance optimization model is proposed for the strength and rigidity design. Numerical modeling about the mathematical formulation of the objective function and design constraints is established and an optimal material layout inside a given domain of the stereolithography (SL) resin pattern is found.Originality/value – Various optimal results of lattice structure configurations are obtained numerically. By comparing the optimal designs with the existing lattice structure configurations, the newly obtained designs have shown better performances both in reducing the stress in the ceramic shell and ...

[1]  V. Braibant,et al.  Structural optimization: A new dual method using mixed variables , 1986 .

[2]  Richard J.M. Hague,et al.  Stresses Created in Ceramic Shells Using Quickcast Models , 1995 .

[3]  Ionut Danaila,et al.  Recent developments in topology design of materials and mechanisms , 2002 .

[4]  W. L. Yao,et al.  Analysis of Shell Cracking in Investment Casting with Laser Stereolithography Patterns , 1999 .

[5]  Weihong Zhang,et al.  Integrated layout design of multi‐component system , 2009 .

[6]  Richard J.M. Hague,et al.  Structural design and resin drainage characteristics of QuickCast 2.0 , 2001 .

[7]  M. Bendsøe,et al.  Topology Optimization: "Theory, Methods, And Applications" , 2011 .

[8]  Niels Olhoff,et al.  Topology optimization of continuum structures: A review* , 2001 .

[9]  Richard J.M. Hague,et al.  Finite Element Analysis and Strain Gauging of the Stereolithography/Investment Casting System , 1996 .

[10]  C. Fleury.  First and second order convex approximation strategies in structural optimization , 1989 .

[11]  Ming-Chuan Leu,et al.  Analysis and design of internal web structure of laser stereolithography patterns for investment casting , 2000 .

[12]  Weihong Zhang,et al.  Scale‐related topology optimization of cellular materials and structures , 2006 .

[13]  Weihong Zhang,et al.  Topology optimization involving thermo-elastic stress loads , 2010 .

[14]  Paul F. Jacobs,et al.  Stereolithography and Other Rp&m Technologies: From Rapid Prototyping to Rapid Tooling , 1995 .

[15]  Sadegh Rahmati,et al.  A novel lattice structure for SL investment casting patterns , 2009 .

[16]  Martin P. Bendsøe,et al.  Optimization of Structural Topology, Shape, And Material , 1995 .