2023 Fiscal Year Final Research Report

Development of a one-stop, high-speed optimal design method that takes into account manufacturability of additive manufacturing

Research Project

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Project/Area Number	21K03826
Research Category	Grant-in-Aid for Scientific Research (C)
Allocation Type	Multi-year Fund
Section	一般
Review Section	Basic Section 18030:Design engineering-related
Research Institution	Osaka Research Institute of Industrial Science and Technology
Principal Investigator	Miki Takao 地方独立行政法人大阪産業技術研究所, 和泉センター, 主任研究員 (80806753)
Co-Investigator(Kenkyū-buntansha)	山田崇恭東京大学, 大学院工学系研究科(工学部), 准教授 (30598222)
Project Period (FY)	2021-04-01 – 2024-03-31
Keywords	トポロジー最適化 / 構造最適化 / 最適設計 / 金属積層造形 / 金属３Dプリンタ / Additive Manufacturing / Design for AM / 有限要素法
Outline of Final Research Achievements	With the aim of advanced manufacturing using metal additive manufacturing (AM), we studied the development of a high-speed optimal design method that takes into account the manufacturability of the AM building process. Specifically, we formulated a mathematical model and constraint equations to take into account the deformation and overhang limitation, targeting the laser powder bed melt-combination method. By incorporating these constraints into topology optimization, we constructed an optimal design method that can simultaneously take into account multiple manufacturability factors such as deformation and overhang limitation. Furthermore, we developed a method to speed up the sensitivity analysis in the optimization calculation. Through numerical demonstrations, it was shown that the optimal structure obtained by this method can suppress the deformation without creating a shape below a threshold angle.
Free Research Field	最適設計
Academic Significance and Societal Importance of the Research Achievements	これまでのトポロジー最適化は軽量・高剛性などの製品性能のみを考慮した最適設計であるため、力学的な観点では最適であっても製造の観点からは最適ではない形状が得られることが多かった。本事業では金属積層造形における造形時の変形や積層角度を考慮するための数理モデルを新たに定式化し、トポロジー最適化に組み込むことで金属積層造形の製造性を考慮した最適設計法を確立した。これにより、当該分野におけるものづくりの効率化・高付加価値化に大きく貢献することに成功した。