Anisotropy in additive manufacturing (AM), particularly in the material extrusion process, plays a crucial role in determining the actual structural performance, including the stiffness and strength of the printed parts. Unless accounted for, anisotropy can compromise the objective performance of topology-optimized structures and allow premature failures for stress-sensitive design domains. This study harnesses process-induced anisotropy in material extrusion-based 3D printing to design and fabricate stiff, strong, and lightweight structures using a two-step framework. First, an AM-oriented anisotropic strength-based topology optimization formulation optimizes the structural geometry and infill orientations, while assuming both anisotropic (i.e., transversely isotropic) and isotropic infill types as candidate material phases. The dissimilar stiffness and strength interpolation schemes in the formulation allow for the optimized allocation of anisotropic and isotropic material phases in the design domain while satisfying their respective Tsai–Wu and von Mises stress constraints. Second, a suitable fabrication methodology realizes anisotropic and isotropic material phases with appropriate infill density, controlled print path (i.e., infill directions), and strong interfaces of dissimilar material phases. Experimental investigations show up to 37% improved stiffness and 100% improved strength per mass for the optimized and fabricated structures. The anisotropic strength-based optimization improves load-carrying capacity by simultaneous infill alignment along the stress paths and topological adaptation in response to high stress concentration. The adopted interface fabrication methodology strengthens comparatively weaker anisotropic joints with minimal additional material usage and multi-axial infill patterns. Furthermore, numerically predicted failure locations agree with experimental observations. The demonstrated framework is general and can potentially be adopted for other additive manufacturing processes that exhibit anisotropy, such as fiber composites.
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Controlling the fracture response of structures via topology optimization: From delaying fracture nucleation to maximizing toughness
It is now a well-established fact that even simple topology variations can drastically change the fracture response of structures. With the objective of gaining quantitative insight into this phenomenon, this paper puts forth a density-based topology optimization framework for the fracture response of structures subjected to quasistatic mechanical loads. One of the two key features of the proposed framework is that it makes use of a complete phase-field fracture theory that has been recently shown capable of accurately describing the nucleation and propagation of brittle fracture in a wide range of nominally elastic materials under a wide range of loading conditions. The other key feature is that the framework is based on a multi-objective function that allows optimizing in a weighted manner: (
) the initial stiffness of the structure, (
) the first instance at which fracture nucleates, and (
) the energy dissipated by fracture propagation once fracture nucleation has occurred. The focus is on the basic case of structures made of a single homogeneous material featuring an isotropic linear elastic behavior alongside an isotropic strength surface and toughness. Novel interpolation rules are proposed for each of these three types of material properties. As a first effort to gain quantitative insight, the framework is deployed to optimize the fracture response of 2D structures wherein the fracture is bound to nucleate in three different types of regions: within the bulk, from geometric singularities (pre-existing cracks and sharp corners), and from smooth parts of the boundary. The obtained optimized structures are shown to exhibit significantly enhanced fracture behaviors compared to those of structures that are optimized according to conventional stiffness maximization. Furthermore, the results serve to reveal a variety of strengthening and toughening mechanisms. These include the promotion of highly porous structures, the formation of tension-compression asymmetric regions, and the removal of cracks and sharp corners. The particular mechanism that is preferred by a given structure, not surprisingly, correlates directly to the elastic, strength, and toughness properties of the material that is made of.
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- Award ID(s):
- 2127134
- NSF-PAR ID:
- 10492195
- Publisher / Repository:
- ScienceDirect
- Date Published:
- Journal Name:
- Journal of the Mechanics and Physics of Solids
- Volume:
- 173
- Issue:
- C
- ISSN:
- 0022-5096
- Page Range / eLocation ID:
- 105227
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract Heterogeneous and complex electronic packages may require unique thermomechanical structures to provide optimal heat guiding. In particular, when a heat source and a heat sink are not aligned and do not allow a direct path, conventional thermal management methods providing uniform heat dissipation may not be appropriate. Here we present a topology optimization method to find thermally conductive and mechanically stable structures for optimal heat guiding under various heat source-sink arrangements. To exploit the capabilities, we consider complex heat guiding scenarios and three-dimensional (3D) serpentine structures to carry the heat with corner angles ranging from 30 deg to 90 deg. While the thermal objective function is defined to minimize the temperature gradient, the mechanical objective function is defined to maximize the stiffness with a volume constraint. Our simulations show that the optimized structures can have a thermal resistance of less than 32% and stiffness greater than 43% compared to reference structures with no topology optimization at an identical volume fraction. The significant difference in thermal resistance is attributed to a thermally dead volume near the sharp corners. As a proof-of-concept experiment, we have created 3D heat guiding structures using a selective laser melting technique and characterized their thermal properties using an infrared thermography technique. The experiment shows the thermal resistance of the thermally optimized structure is 29% less than that of the reference structure. These results present the unique capabilities of topology optimization and 3D manufacturing in enabling optimal heat guiding for heterogeneous systems and advancing the state-of-the-art in electronics packaging.more » « less
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null (Ed.)Recent theoretical and computational progress has led to unprecedented understanding of symmetry-breaking instabilities in 2D dynamic fracture. At the heart of this progress resides the identification of two intrinsic, near crack tip length scales — a nonlinear elastic length scale ℓ and a dissipation length scale ξ — that do not exist in Linear Elastic Fracture Mechanics (LEFM), the classical theory of cracks. In particular, it has been shown that at a propagation velocity v of about 90% of the shear wave-speed, cracks in 2D brittle materials undergo an oscillatory instability whose wavelength varies linearly with ℓ, and at larger loading levels (corresponding to yet higher propagation velocities), a tip-splitting instability emerges, both in agreements with experiments. In this paper, using phase-field models of brittle fracture, we demonstrate the following properties of the oscillatory instability: (i) It exists also in the absence of near-tip elastic nonlinearity, i.e. in the limit ℓ→0, with a wavelength determined by the dissipation length scale ξ. This result shows that the instability crucially depends on the existence of an intrinsic length scale associated with the breakdown of linear elasticity near crack tips, independently of whether the latter is related to nonlinear elasticity or to dissipation. (ii) It is a supercritical Hopf bifurcation, featuring a vanishing oscillations amplitude at onset. (iii) It is largely independent of the phenomenological forms of the degradation functions assumed in the phase-field framework to describe the cohesive zone, and of the velocity-dependence of the fracture energy Γ(v) that is controlled by the dissipation time scale in the Ginzburg-Landau-type evolution equation for the phase-field. These results substantiate the universal nature of the oscillatory instability in 2D. In addition, we provide evidence indicating that the tip-splitting instability is controlled by the limiting rate of elastic energy transport inside the crack tip region. The latter is sensitive to the wave-speed inside the dissipation zone, which can be systematically varied within the phase-field approach. Finally, we describe in detail the numerical implementation scheme of the employed phase-field fracture approach, allowing its application in a broad range of materials failure problems.more » « less
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1016/j.jmps.2023.105227
