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Ranjan, R. (author), Chen, Z. (author), Ayas, C. (author), Langelaar, M. (author), van Keulen, A. (author)Overheating is a major issue especially in metal Additive Manufacturing (AM) processes, leading to poor surface quality, lack of dimensional precision, inferior performance and/or build failures. A 3D density-based topology optimization (TO) method is presented which addresses the issue of local overheating during metal AM. This is achieved...journal article 2023
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Delissen, A.A.T.M. (author), van Keulen, A. (author), Langelaar, M. (author)The design of high-performance mechatronic systems is very challenging, as it requires delicate balancing of system dynamics, the controller, and their closed-loop interaction. Topology optimization provides an automated way to obtain systems with superior performance, although extension to simultaneous optimization of both topology and...journal article 2023
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Pressmair, Nadine (author), Xia, Yi (author), Wu, Hongfei (author), Langelaar, M. (author), Hendriks, M.A.N. (author), Majdouba, Ahmad (author), Mogra, Mihir (author), Grisaro, Hezi (author), Amir, Oded (author), Kromoser, Benjamin (author)Concrete, as the most widely used construction material, is associated with a high environmental impact. Within the present study, structural optimization is the method of choice to counter this issue. The entire process, from optimization, to design, experiments and numerical simulation is outlined. Embedded in the framework of a design...journal article 2023
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Fransen, M.P. (author), Langelaar, M. (author), Schott, D.L. (author)In design optimization of bulk handling equipment (BHE) we generally focus on the mean performance of the equipment. However, granular materials behave stochastic due to irregularities in particle shape and size which leads to stochastic performance of the equipment. To include the stochastic performance we propose robust metamodel-based...journal article 2023
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Theulings, M.J.B. (author), Langelaar, M. (author), van Keulen, A. (author), Maas, Robert (author)Modeling of fluid flows in density-based topology optimization forms a longstanding challenge. Methods based on the Navier–Stokes equations with Darcy penalization (NSDP equations) are widely used in fluid topology optimization. These methods use porous materials with low permeability to represent the solid domain. Consequently, they suffer...journal article 2023
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Ranjan, R. (author), Ayas, C. (author), Langelaar, M. (author), van Keulen, A. (author)A novel constraint to prevent local overheating is presented for use in topology optimization (TO). The very basis for the constraint is the Additive Manufacturing (AM) process physics. AM enables fabrication of highly complex topologically optimized designs. However, local overheating is a major concern especially in metal AM processes...journal article 2022
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Fransen, M.P. (author), Langelaar, M. (author), Schott, D.L. (author)In calibration of model parameters for discrete element method (DEM) based models the focus lies on matching the mean key performance indicator (KPI) values from laboratory experiments to those from simulation results. However, due to the stochastic nature of granular processes experimental results can show large variances. To include...journal article 2022
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Xia, Yi (author), Langelaar, M. (author), Hendriks, M.A.N. (author)Strut-and-Tie modelling (STM) has been widely applied to design D-regions of reinforced concrete structures. For economic and environmental reasons there is a need for optimized Strut-and-Tie models. How to optimize Strut-and-Tie models considering multiple load combinations has not been investigated extensively in the literature. In order to...journal article 2022
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Kumar, Prabhat (author), Langelaar, M. (author)This paper presents a robust density-based topology optimization approach for synthesizing pressure-actuated compliant mechanisms. To ensure functionality under manufacturing inaccuracies, the robust or three-field formulation is employed, involving dilated, intermediate and eroded realizations of the design. Darcy's law in conjunction with a...journal article 2022
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Giele, R.J.P. (author), van Keulen, A. (author), Langelaar, M. (author)Topology optimization methods improve the structural performance of components. However, in food processing, medical, high-precision, and other industries' designs should also fulfil the requirement of being cleanable. An important aspect of cleanability is drainability, which entails that fluids can always run off the structure under just...journal article 2022
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Delissen, A.A.T.M. (author), Boots, Elwin (author), Laro, Dick (author), Kleijnen, Harry (author), van Keulen, A. (author), Langelaar, M. (author)The design of high-precision motion stages, which must exhibit high dynamic performance, is a challenging task. Manual design is difficult, time-consuming, and leads to sub-optimal designs that fail to fully exploit the extended geometric freedom that additive manufacturing offers. By using topology optimization and incorporating all...journal article 2022
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Koppen, S. (author), van der Kolk, M. (author), van den Boom, S.J. (author), Langelaar, M. (author)Real-world structural optimisation problems involve multiple loading conditions and design constraints, with responses typically depending on states of discretised governing equations. Generally, one uses gradient-based nested analysis and design approaches to solve these problems. Herein, solving both physical and adjoint problems dominates...journal article 2022
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Mishra, V. (author), Ayas, C. (author), Langelaar, M. (author), van Keulen, A. (author)Topology optimization typically generates designs that exhibit significant geometrical complexity, which can pose difficulties for manufacturing and assembly. The number of occurrences of an important design feature, in particular intersections, increases with geometrical complexity. Intersections are essential for load transfer in many...journal article 2022
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Koppen, S. (author), Langelaar, M. (author), van Keulen, A. (author)High-tech equipment critically relies on flexures for precise manipulation and measurement. Through elastic deformation, flexures offer extreme position repeatability within a limited range of motion in their degrees of freedom, while constraining motion in the degrees of constraint. Topology optimization proves a prospective tool for the...journal article 2022
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Koppen, S. (author), Langelaar, M. (author), van Keulen, A. (author)In topology optimization, the state of structures is typically obtained by numerically evaluating a discretized PDE-based model. The degrees of freedom of such a model can be partitioned in free and prescribed sets to define the boundary conditions. A multi-partition problem involves multiple partitions of the same discretization, typically...journal article 2022
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Misiun, Grzegorz (author), van de Ven, E.A. (author), Langelaar, M. (author), Geijselaers, Hubert (author), van Keulen, A. (author), van den Boogaard, Ton (author), Ayas, C. (author)An important cause of failure in powder bed additive manufacturing is the distortion of the part due to thermal shrinkage during printing and the relaxation of residual stresses after its release from the base plate. In this paper, Additive Manufacturing simulations are coupled with Topology Optimization in order to generate designs that are...journal article 2021
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van de Ven, E.A. (author), Maas, Robert (author), Ayas, C. (author), Langelaar, M. (author), van Keulen, A. (author)Although additive manufacturing (AM) allows for a large design freedom, there are some manufacturing limitations that have to be taken into consideration. One of the most restricting design rules is the minimum allowable overhang angle. To make topology optimization suitable for AM, several algorithms have been published to enforce a minimum...journal article 2021
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Koppen, S. (author), Hoes, Emma (author), Langelaar, M. (author), Frecker, Mary I. (author)Compliant mechanisms are crucial components in current and future high-precision applications. Topology optimization and additive manufacturing offer freedom to design complex compliant mechanisms that were impossible to realize using conventional manufacturing. Design for additive manufacturing constraints, such as the maximum overhang angle...conference paper 2021
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van de Ven, E.A. (author), Ayas, C. (author), Langelaar, M. (author), Maas, Robert (author), van Keulen, A. (author)Additive manufacturing (AM) and topology optimization (TO) have a synergetic relation, as AM can produce complex TO designs, and TO provides high-performance parts that utilize the form freedom provided by AM. Recently, TO has been tailored more toward AM with the inclusion of the minimum allowable overhang angle as a design constraint:...journal article 2021
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Kumar, P. (author), Langelaar, M. (author)This article presents a density-based topology optimization method for designing three-dimensional (3D) compliant mechanisms (CMs) and loadbearing structures with design-dependent pressure loading. Instead of interface-tracking techniques, the Darcy law in conjunction with a drainage term is employed to obtain pressure field as a function of...journal article 2021