TY - JOUR
T1 - Optimal toolpath design of additive manufactured composite cylindrical structures
AU - Fernandez, Felipe
AU - Lewicki, James P.
AU - Tortorelli, Daniel A.
N1 - Views expressed here do not necessarily reflect the opinion of the United States Government, the United States Department of Energy, or the Lawrence Livermore National Laboratory. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE-AC52 07NA27344 . Lawrence Livermore National Security, LLC, USA . cf. ref number LLNL-JRNL-815097 .
PY - 2021/4/1
Y1 - 2021/4/1
N2 - Structural design optimization for additive manufacturing is primarily focused on planar layer-by-layer processes and design of composite cylindrical structures does not often accommodate manufacturing constraints. In this study, we propose to optimize the toolpath trajectory of additively manufactured composite cylinders comprised of multiple thin cylindrical annuli. Our printing process is based on direct ink writing in which short carbon fibers in a thermoset resin are extruded through a moving nozzle to build up a structure. Since the fibers are primarily aligned in the flow direction of the extrudate, the printing trajectory influences the material properties of the composite structure. To accommodate this, we define the toolpaths as contours of parameterized level-set functions. This parameterization allows us to optimize the material properties and impose manufacturing constraints such as no-overlap, no-sag, minimum radius of curvature, and continuity of the toolpaths. Several examples illustrate the optimization procedure.
AB - Structural design optimization for additive manufacturing is primarily focused on planar layer-by-layer processes and design of composite cylindrical structures does not often accommodate manufacturing constraints. In this study, we propose to optimize the toolpath trajectory of additively manufactured composite cylinders comprised of multiple thin cylindrical annuli. Our printing process is based on direct ink writing in which short carbon fibers in a thermoset resin are extruded through a moving nozzle to build up a structure. Since the fibers are primarily aligned in the flow direction of the extrudate, the printing trajectory influences the material properties of the composite structure. To accommodate this, we define the toolpaths as contours of parameterized level-set functions. This parameterization allows us to optimize the material properties and impose manufacturing constraints such as no-overlap, no-sag, minimum radius of curvature, and continuity of the toolpaths. Several examples illustrate the optimization procedure.
KW - Additive manufacturing
KW - Cylinders
KW - Manufacturing constraints
KW - Nonplanar
KW - Structural composites
KW - Toolpath optimization
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U2 - 10.1016/j.cma.2021.113673
DO - 10.1016/j.cma.2021.113673
M3 - Article
AN - SCOPUS:85099610360
SN - 0045-7825
VL - 376
JO - Computer Methods in Applied Mechanics and Engineering
JF - Computer Methods in Applied Mechanics and Engineering
M1 - 113673
ER -