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Le travail concerne l'adaptation de la phase de développement en vue d'une impression 3D performante. Le travail considère les contraintes d'origine thermique en plus des constraintes d'utilisation en phase opérationnelle.

3D printing --- Computer Aided Manufacturing --- Topology Optimization --- Ingénierie, informatique & technologie > Ingénierie mécanique

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This book covers additive manufacturing of polymers, metals, ceramics, fiber reinforced polymer composites, energy harvesting materials, and biomaterials. Hybrid manufacturing is discussed. Topology optimization methodology is described and finite element software examples are provided. The book is ideal for graduate students and career starters in the industry.

Additive manufacturing. --- Three-dimensional printing. --- 3D printing technologies. --- Additive Manufacturing. --- Topology optimization methodology.

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In a context of climate change, energy economy and better resources use, the automotive
industry stands inside a major revolution. Car manufacturers strive to innovate to
build lighter vehicles, aiming at reductions of carbon dioxide emissions and improved
efficiency.
Topology optimization, introducing material only where needed, perfectly fits into this
perspective. The work described here is related to the mass reduction of a wheel carrier.
This component, among the most critical inside the suspension system, is submitted
to a high number of requirements and load cases, related to different mechanical fields
(frequencies, stresses, etc.). Manufacturing of this part through casting also matters.
To maximize the odds of obtaining a design satisfying the constraints, an incremental
approach will be adopted to develop a formulation that could hopefully be extended to
other components. Dans un contexte de changement climatique, d’économie d’énergie et de meilleure utilisation
des ressources, l’industrie automobile se trouve au coeur d’une révolution majeure.
Les constructeurs s’efforcent d’innover afin de rendre leurs véhicules plus légers dans un
but de réduction des émissions de dioxyde de carbone et d’efficacité accrue.
L’optimisation topologique, introduisant le matériau uniquement là où il est nécessaire,
s’inscrit parfaitement dans cette perspective. Le travail décrit ici concerne l’allègement
d’un porte-roue. Cette pièce, parmi les plus critiques du système de suspension, est
soumise à un grand nombre d’exigences et de cas de charge, touchant à différentes disciplines
de la mécanique (fréquences, contraintes, etc.). Il importe également de considérer
la fabrication par coulage de cet élément.
Afin de maximiser les chances d’obtenir un design satisfaisant la demande, une approche
incrémentale sera adoptée afin de développer une formulation qui pourra éventuellement
être étendue à d’autres composants.

Mechanics --- Topology optimization --- Automotive suspensions --- Manufacturing --- Stresses --- Frequencies --- Mécanique --- Optimisation topologique --- Suspensions automobiles --- Fabrication --- Contraintes --- Fréquences --- Ingénierie, informatique & technologie > Ingénierie mécanique

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Nowadays, increasingly concerning environmental problems, energy economy
and raw resource scarcity urge automotive manufacturers to rethink the design
of chassis and body components in such a way that the material is used to its
full potential.
With this mindset, Topology Optimization proved its usefulness as an efficient
design tool for sustainable and lightweight designs of chassis components,
achieving better fuel economy through mass reduction. However, the initial
design provided by the topology optimization algorithm is most frequently relatively
complex, requiring additional manual post-processing by manufacturing
experts. In the pursuit of ready-to-manufacture, lightweight parts for mass
production, this study focuses on the development of a flexible and large-scale
Python code for topology optimization with integrated casting constraints.
The proposed method uses the open-source FEniCS Project as finite element
software, allowing the usage of PETSc as linear algebra back-end for better
efficiency.
The introduction of casting constraints such as directional molding, splitdrawing,
minimum hole and pocket size, minimum member size and draft
angle were considered, allowing the generation of ready-to-cast optimized parts.
The benefit of such as algorithm is the significant reduction of time spent
in post-processing, leading to faster development times of lightweight and
innovative designs. De nos jours, les problèmes environnementaux de plus en plus préoccupants,
l’économie d’énergie et la rareté des matières premières poussent les constructeurs
automobiles à repenser la conception des composants de châssis et de
carrosserie de manière à utiliser le matériau à son plein potentiel.
Dans cet état d’esprit, l’optimisation topologique a prouvé son utilité en tant
qu’outil de conception efficace pour la conception de composants de châssis
durables et légèrs, permettant une meilleure économie de carburant grâce à
la réduction de la masse. Cependant, la conception initiale fournie par l’algorithme
d’optimisation topologique est le plus souvent relativement complexe,
ce qui nécessite un post-traitement manuel supplémentaire par les experts en
fabrication. Dans la recherche de pièces légères prêtes à être fabriquées pour
la production de masse, cette étude se concentre sur le développement d’un
code Python flexible pour l’optimisation topologique de grande échelle avec
des contraintes de moulage intégrées. La méthode proposée utilise le projet
open-source FEniCS comme logiciel d’éléments finis, permettant l’utilisation
de PETSc comme back-end d’algèbre linéaire pour une meilleure efficacité.
L’introduction de contraintes de coulée telles que le moulage directionnel,
l’emboutissage fractionné, la taille minimale des trous et des poches, la taille
minimale des éléments et l’angle de dépouille a été prise en compte, permettant
la génération de pièces optimisées prêtes à couler. L’avantage d’un tel algorithme
est la réduction significative du temps passé en post-traitement, ce qui
permet d’accélérer le développement de conceptions légères et innovantes.

topology optimization --- manufacturing --- casting --- molding --- automotive --- lightweight --- mass reduction --- sustainability --- chassis components --- optimisation topologique --- fabrication --- coulée --- moulage --- automobile --- légèreté --- réduction de la masse --- durabilité --- composants de châssis --- Ingénierie, informatique & technologie > Ingénierie civile

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Additive manufacturing (AM), more commonly known as 3D printing, has grown trememdously in recent years. It has shown its potential uses in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing, and local on-demand manufacturing are just some of its current benefits. The development of new materials and equipment has opened up new application possibilities, and equipment is quicker and cheaper to use when utilizing the new materials launched by vendors and material developers. AM has become more critical for the industry but also for academics. Since AM offers more design freedom than any other manufacturing process, it provides designers with the challenge of designing better and more efficient products.

Technology: general issues --- History of engineering & technology --- additive manufacturing --- modular design --- design-for-manufacturability --- design optimization --- part consolidation --- product re-design --- topology optimization --- design for additive manufacturing --- 3D printing --- aerospace --- full-life cycle manufacturing flow --- airfoil --- carbon fiber tubes --- telescoping spars --- chevrons --- porous scaffold design --- tetrahedral implicit surface modeling --- triply periodic minimal surface --- selective laser melting (SLM) --- Ti6Al4V --- structure–property relationship --- microstructure --- Hall–Petch relationship --- n/a --- structure-property relationship --- Hall-Petch relationship