TY - GEN
T1 - Design for additive manufacturing of cellular compliant mechanism using thermal history feedback
AU - Khurana, Jivtesh
AU - Hanks, Bradley
AU - Frecker, Mary
N1 - Funding Information:
The first author gratefully acknowledges the support of the Penn State’s College of Engineering Research Initiative (CERI) program for funding this research. We also acknowledge the support of 3D Systems and Dr. Ted Reutzel, and Alex Dunbar from the Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) at Penn State University for their assistance in printing preliminary metal C3M prototypes.
Publisher Copyright:
Copyright © 2018 ASME.
PY - 2018
Y1 - 2018
N2 - With growing interest in metal additive manufacturing, one area of interest for design for additive manufacturing is the ability to understand how part geometry combined with the manufacturing process will affect part performance. In addition, many researchers are pursuing design for additive manufacturing with the goal of generating designs for stiff and lightweight applications as opposed to tailored compliance. A compliant mechanism has unique advantages over traditional mechanisms but previously, complex 3D compliant mechanisms have been limited by manufacturability. Recent advances in additive manufacturing enable fabrication of more complex and 3D metal compliant mechanisms, an area of research that is relatively unexplored. In this paper, a design for additive manufacturing workflow is proposed that incorporates feedback to a designer on both the structural performance and manufacturability. Specifically, a cellular contact-aided compliant mechanism for energy absorption is used as a test problem. Insights gained from finite element simulations of the energy absorbed as well as the thermal history from an AM build simulation are used to further refine the design. Using the proposed workflow, several trends on the performance and manufacturability of the test problem are determined and used to redesign the compliant unit cell. When compared to a preliminary unit cell design, a redesigned unit cell showed decreased energy absorption capacity of only 7.8% while decreasing thermal distortion by 20%. The workflow presented provides a systematic approach to inform a designer about methods to redesign an AM part.
AB - With growing interest in metal additive manufacturing, one area of interest for design for additive manufacturing is the ability to understand how part geometry combined with the manufacturing process will affect part performance. In addition, many researchers are pursuing design for additive manufacturing with the goal of generating designs for stiff and lightweight applications as opposed to tailored compliance. A compliant mechanism has unique advantages over traditional mechanisms but previously, complex 3D compliant mechanisms have been limited by manufacturability. Recent advances in additive manufacturing enable fabrication of more complex and 3D metal compliant mechanisms, an area of research that is relatively unexplored. In this paper, a design for additive manufacturing workflow is proposed that incorporates feedback to a designer on both the structural performance and manufacturability. Specifically, a cellular contact-aided compliant mechanism for energy absorption is used as a test problem. Insights gained from finite element simulations of the energy absorbed as well as the thermal history from an AM build simulation are used to further refine the design. Using the proposed workflow, several trends on the performance and manufacturability of the test problem are determined and used to redesign the compliant unit cell. When compared to a preliminary unit cell design, a redesigned unit cell showed decreased energy absorption capacity of only 7.8% while decreasing thermal distortion by 20%. The workflow presented provides a systematic approach to inform a designer about methods to redesign an AM part.
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U2 - 10.1115/DETC2018-85819
DO - 10.1115/DETC2018-85819
M3 - Conference contribution
AN - SCOPUS:85057020178
T3 - Proceedings of the ASME Design Engineering Technical Conference
BT - 44th Design Automation Conference
PB - American Society of Mechanical Engineers (ASME)
T2 - ASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018
Y2 - 26 August 2018 through 29 August 2018
ER -