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research-article

Integration of Design for Manufacturing methods with Topology Optimization in Additive Manufacturing

[+] Author and Article Information
Rajit Ranjan

Center for Global Design and Manufacturing, Department of Mechanical and Materials Engineering, University of Cincinnati, Cincinnati, OH 45221
ranjanrt@mail.uc.edu

Rutuja Samant

Center for Global Design and Manufacturing, Department of Mechanical and Materials Engineering, University of Cincinnati, Cincinnati, OH 45221
samantrv@mail.uc.edu

Sam Anand

Center for Global Design and Manufacturing, Department of Mechanical and Materials Engineering, University of Cincinnati, Cincinnati, OH 45221
sam.anand@uc.edu

1Corresponding author.

ASME doi:10.1115/1.4035216 History: Received February 06, 2016; Revised November 08, 2016

Abstract

Additive Manufacturing (AM) processes are used to fabricate complex geometries using a layer by layer material deposition technique. These processes are recognized for creating complex shapes which are difficult to manufacture otherwise and enables designers to be more creative with their designs. However, as AM is still in its developing stages, relevant literature with respect to design guidelines for AM is not readily available. This paper proposes a novel design methodology which can assist designers in creating parts that are friendly to additive manufacturing. The research includes formulation of design guidelines by studying the relationship between input part geometry and AM process parameters. Two cases are considered for application of the developed design guidelines. The first case presents a feature graph based design improvement method in which a Producibility Index (PI) concept is introduced to compare AM friendly designs. This method is useful for performing manufacturing validation of pre-existing designs and modifying it for better manufacturability through AM processes. The second approach presents a topology optimization based design methodology which can help designers in creating entirely new lightweight designs which can be manufactured using AM processes with ease. Application of both these methods is presented in the form of case studies depicting design evolution for increasing manufacturability and associated Producibility Index of the part.

Copyright (c) 2016 by ASME
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