Topology optimization of three-dimensional shell structures made of continuous fiber reinforced composites considering manufacturing constraints

IF 8.1 2区材料科学 Q1 ENGINEERING, MANUFACTURING

Composites Part A: Applied Science and Manufacturing Pub Date : 2025-05-28 DOI:10.1016/j.compositesa.2025.109069

Zhe Yang , Tao Luo , Zhongsen Zhang , Luncao Li , Kunkun Fu , Yan Li

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引用次数: 0

Abstract

This study proposed a modified 3D Solid Orthotropic Material with Penalization (SOMP) topology optimization method specifically designed for 3D shell structures made of continuous fiber reinforced composites (CFRCs), while considering the manufacturing constraints associated with 3D printing. The optimization results demonstrated that proposed method effectively aligns the fiber orientations of the designed topological structures parallel to each predetermined slice layer. This alignment ensures feasibility in path planning, thereby facilitating the 3D printing of the optimized CFRC shell structures. Then, an arched CFRC shell structure was optimized using the proposed modified 3D SOMP method and fabricated with a multi-axis 3D printer following a continuous fiber printing trajectory derived from an offset path planning approach. Mechanical testing demonstrated that the global stiffnesses of these 3D-printed CFRC shell structures are in agreements with the numerical results obtained after topology optimization with a discrepancy of 12.7%. This demonstrates a strong alignment between the optimization design and the manufacture.

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考虑制造约束的连续纤维增强复合材料三维壳结构拓扑优化

本研究针对连续纤维增强复合材料（CFRCs）的三维壳体结构，提出了一种改进的三维固体正交异性材料惩罚（SOMP）拓扑优化方法，同时考虑了3D打印相关的制造限制。优化结果表明，所提出的方法有效地使所设计拓扑结构的纤维取向平行于每个预定切片层。这种对齐确保了路径规划的可行性，从而便于优化后的CFRC壳结构的3D打印。然后，利用改进的3D SOMP方法优化了拱形CFRC壳体结构，并利用多轴3D打印机按照偏移路径规划方法导出的连续纤维打印轨迹进行了加工。力学试验表明，3d打印CFRC壳结构的整体刚度与拓扑优化后的数值计算结果吻合较好，误差为12.7%。这证明了优化设计和制造之间的强烈一致性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.