Research On Lightweight Design Method Of Mechanical Structure For Additive Manufacturing

Additive manufacturing(AM)technology,which is the remarkable achievement of the third scientific and technological revolution,is gradually changing the mode of production and life in the world.However,the traditional mechanical structure using additive manufacturing method to manufacturing cannot show the advantages of additive manufacturing perfectly,so many people put forward the structural optimization for additive manufacturing.Design for additive manufacturing(DFAM)is an important problem in current additive Manufacturing field,it is essential for additive manufacturing product to consider the whole life cycle and manufacturing economy.In this paper puts forward methods of lightweight structure for additive manufacturing,and verifies its feasibility with some specific examples.In topology optimization technology,this paper analyzed the topology optimization theory and combined it with the additive manufacturing which has unique advantages of manufacturing will make structure optimized better.An example of oil block is introduced,the lightweight design of the structure is carried out from the view of multi physical field coupling,and optimized result is directly transformed into STL file for slicing and printing,in order to verify the feasibility of optimized structure.Optimization result is that the oil block reduces weight about 55% under the condition of little stress variation.The whole process reduces the life cycle of the product design,and can also make the product lighter,which has great positive significance.In the lattice structure design,this paper proposed single parameter optimization design method which based on stress distribution.The core of this method is the discrete main body,according to the distribution of the design space unit stress.Design space will be divided into different spatial structure,then according to the stress range of different body filling into the different lattice structure.Finally,integrated the dispersed parts into a whole.Choose the honeycomb structure as the basic optimization example and show the specific optimization design steps.In this method,the optimization result is lighter than the original traditional cellular structure under the condition of the maximum stress of the structure changes little.In order to further verify the feasibility of the optimization method,the support plate of swing arm track robot is lightweight designed.The results show that optimized structure is 42.3%lighter than original structure,under the condition of the little change of maximum stress.Topology optimization technology has made great progress,however,regard to additivemanufacturing,optimized high angle overhang structure cannot printing into model perfectly.Even the support structure is added,the material connection between different layers is not too tight,so the design of non-uniform lattice structure for AM is also studied in this paper.