Space-time topology optimization for multi-axis additive manufacturing

Abstract

This dissertation develops an optimization framework for multi-axis additive manufacturing, with a particular focus on wire arc additive manufacturing (WAAM). It introduces the novel space-time topology optimization approach that integrates structural design and fabrication sequence planning by defining material distribution across both spatial and temporal dimensions.
In this framework, a pseudo-density field defines the structural layout, while a pseudo-time field encode the fabrication sequence, offering detailed insights into the layer-by-layer manufacturing process. Two key advancements are developed in order to improve the manufacturability: First, a thermal regularization method is proposed to ensure a smooth and continuous pseudo-time field without local minima. Second, a layer geometry control scheme is implemented to improve the consistency of the layer dimensions.
The framework is further adopted to address challenges associated with residual stress and thermal-induced distortion in WAAM, employing the inherent strain method as a simplified process simulation model. In addition, the anisotropic nature of material properties in WAAM is considered, enabling the rational alignment of material deposition orientation to enhance performance.
Numerical results demonstrate the feasibility and effectiveness of the proposed optimization framework, inspiring the exploration of the innovative potential offered by multi-axis additive manufacturing.