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Design for additive manufacturing including machining constraints: A case study of topology optimization including machining forces

Benoist, Vincent and Baili, Maher and Arnaud, Lionel Design for additive manufacturing including machining constraints: A case study of topology optimization including machining forces. (2019) In: First International Conference on Innovative Materials, Manufacturing, and Advanced Technologies : IMMAT'2019, 17 October 2019 - 19 October 2019 (Monastir, Tunisia).

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Abstract

Metal additive manufacturing is a major field of study and innovation. In aerospace industry a lot of effort is made to modelise and optimize the designs. In this context, despite all efforts, metal additive manufacturing (especially SLM) still produce part generally considered as raw parts which still have some surfaces to be machined in order to obtain the required geometrical quality. Despite sometimes, great complexity and cost related to the finishing process, the machining stage is never taken into account in the design process, especially using the topological optimization approach. In this paper, a new Design for Additive Manufacturing (DFAM) method is proposed in order to optimize the design stage including topological optimization, machining, geometrical and mechanical constraints. It is shown on a typical aeronautical part that cutting forces may be the greatest forces during all the part life-time. Using 2 different topological optimization software (Inspire / Abaqus Tosca) it is shown that it is possible to consider most of the machining constrains to only slightly modify the initial design and thus simplify the machining stage and reduce possible failure during machining. Finally, machining test, geometrical accuracy control and pressure test validate the approach.

Item Type:Conference or Workshop Item (Paper)
HAL Id:hal-02359933
Audience (conference):International conference proceedings
Uncontrolled Keywords:
Institution:Université de Toulouse > Institut National Polytechnique de Toulouse - Toulouse INP (FRANCE)
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Deposited On:25 Oct 2019 08:04

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