面向增材制造的新型蜂窝夹芯结构拓扑优化设计  

Topology optimization design of new honeycomb sandwich structures for additive manufacturing

作　　者：蒋国璋 刘朴湧[1,2] 张严 段现银 谢寒冰 JIANG Guozhang;LIU Puyong;ZHANG Yan;DUAN Xianyin;XIE Hanbing(Key Laboratory of Metallurgical Equipment and Control,Technology of Ministry of Education,Wuhan University of Science and Technology,Wuhan 430081,China; Key Laboratory of Mechanical Transmission and Manufacturing Engineering of Hubei Province,Wuhan University of Science and Technology,Wuhan 430081,China; Precision Manufacturing Institute,Wuhan University of Science and Technology,Wuhan 430081,China)

机构地区：[1]武汉科技大学冶金装备及其控制教育部重点实验室,湖北武汉430081 [2]武汉科技大学机械传动与制造工程湖北省重点实验室,湖北武汉430081 [3]武汉科技大学精密制造研究院,湖北武汉430081

出　　处：《粉末冶金工业》2024年第4期134-140,共7页Powder Metallurgy Industry

基　　金：国家自然科学基金资助项目(52205280)

摘　　要：增材制造是实现蜂窝结构的高效率、高精度制造的新兴技术,然而传统基于设计经验和力学试验的蜂窝夹芯设计方法,难以充分挖掘材料潜力、创新结构构型,导致蜂窝结构承载能力较差。本文提出了一种面向增材制造的新型蜂窝夹芯结构拓扑优化设计方法。采用数值均匀化理论预测蜂窝夹芯微结构的宏观等效弹性性能,随后以蜂窝夹芯微结构的剪切模量或体积模量最大化为优化目标,材料用量为约束条件,建立面向增材制造的蜂窝夹芯微结构拓扑优化设计模型;在拓扑优化模型灵敏度求解过程中施加灵敏度信息一致性约束,获得具有截面一致性的蜂窝夹芯结构,便于增材制造的高质量成形;算例结果表明,所提方法设计的新型蜂窝夹芯结构的剪切模量比传统六边形蜂窝和类蜂窝分别提高了58.62%和60.08%,体积模量分别提高了11.91%、31.82%。所提方法通过充分挖掘蜂窝夹芯的设计空间,显著提升了其力学性能,满足了增材制造的工艺要求。研究成果为高承载蜂窝夹芯结构设计和构型创新提供理论参考。Additive manufacturing,as an emerging technology,offers an efficient and high-precision approach for fabricating honeycomb structures.However,traditional honeycomb core design methods based on design experience and mechanical experiments often fall short in fully exploiting material potential and innovating structural configurations,leading to suboptimal load-bearing capacity of honeycomb structures.This paper introduced a new topology optimization design method for honeycomb core structures tailored for additive manufacturing.Utilizing numerical homogenization theory,the macroscopic equivalent elastic properties of honeycomb core microstructures were predicted.Subsequently,the optimization objective was set to maximize the shear modulus or bulk modulus of the honeycomb core microstructure,with material usage as a constraint,establishing a topology optimization model for honeycomb core microstructures tailored for additive manufacturing.During the sensitivity analysis in the topology optimization model,consistency constraints on sensitivity information were imposed to achieve honeycomb core structures with cross-sectional consistency,facilitating high-quality forming in additive manufacturing.Case study results demonstrate that the proposed method increases the shear modulus of the designed novel honeycomb core structure by 58.62%and 60.08%compared to traditional hexagonal and honeycomb-like honeycomb structures,with bulk modulus increases of 11.91%and 31.82%,respectively.The method,by fully exploring the design space of honeycomb cores,significantly enhances their mechanical performance,meeting the requirements of additive manufacturing processes.The research findings provide theoretical references for the design and configuration innovation of high-load honeycomb core structures.

关 键 词：增材制造 蜂窝夹芯 微结构 拓扑优化 数值均匀化 

分 类 号：TB33[一般工业技术—材料科学与工程]