Improved design methodology for additive manufacturing including machining load cases: application to an aeronautical workpiece

Vincent Benoist (1) , Lionel Arnaud (1) , Maher Baili (1) , Jean-Pierre Faye (1)

1 LGP - Laboratoire Génie de Production

This paper focuses on the impact of post processing machining and mounting / unmounting phases on topological optimization methods. In addition to the classical load cases taken into account in optimization methods, various static and vibratory forces occurring during machining phases and manipulations, are also considered. Results of the topology optimization show that the most significant load case for the aeronautical part considered is indeed one of the post processing machining operations and it has a strong impact on the optimized shape. This result shows that such post processing phases have to be taken into account, whatever they represent supports removal or finishing surfaces. Supports are most of the time mandatory but their removal by machining operation may be require a non-negligible time, skill and cost. In this paper the machining operations are first studied through their effects on topological optimization. Then the cutting phenomenon is numerically modeled to explore various options of build supports and prevent the part from damages due to tearing. Finally, this paper demonstrates that cutting forces analysis should encourage designers (i.e. topology optimizers) and machinists to interact, in order to minimize the total cost of the additive manufactured workpiece.

Mots clés: DFAM; Topology optimization; Support; Cutting force model; Vibrations; Stiffness

Domaines: Optimisation et contrôle [math.OC]; Autre

Vincent Benoist, Lionel Arnaud, Maher Baili, Jean-Pierre Faye. Improved design methodology for additive manufacturing including machining load cases: application to an aeronautical workpiece. MUGV & Manufacturing’21, Jun 2018, Bordeaux, France. pp.0. ⟨hal-02968047⟩