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Towards multiscale topology optimization for additively manufactured components using implicit slicing

Towards multiscale topology optimization for additively manu...

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ASME 2017 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2017

作者： Steuben, John C. Lliopoulos, Athanasios P. Michopoulos, John G. Naval Research Laboratory Computational Multiphysics Systems Laboratory Center of Materials Physics and Technology WashingtonDC20375 United States

ISBN: (纸本)9780791858110

Additive Manufacturing (AM) encompasses a set of fabrication technologies that are being used with increasing frequency in a wide variety of scientific and industrial pursuits. These technologies, which operate by successive additions of material to a domain, enable the manufacture of highly complex geometries that would otherwise be unrealizable. However, the material micro and mesa-structures generated by AM processes differ remarkably from those that arise from conventional techniques and occasionally introduce unwanted functional features;this has been an obstacle to the use of AM in some applications. In the present work, we propose a multiscale method that utilizes the unique meso-scale structuring capabilities of implicit slicers for AM, in conjunction with existing topology optimization tools for the macro-scale, in order to generate functional components. The use of this method is demonstrated on the example of a hand tool. We discuss the applications of this methodology, its current limitations, and the future work required to enable its widespread use. © 2017 ASME.

关键词： Topology

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TOWARDS A computational FRAMEWORK FOR HYPERVELOCITY-INDUCED ATMOSPHERIC PLASMA MODELING

TOWARDS A COMPUTATIONAL FRAMEWORK FOR HYPERVELOCITY-INDUCED ...

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ASME 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2024

作者： Graber, B.D. Iliopoulos, A.P. Michopoulos, J.G. Steuben, J.C. Birnbaum, A.J. Apetre, N.A. Computational Multiphysics Systems Laboratory Materials Science and Technology Division U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791888346

The work presented in this paper estimates the spectral radiance emitted from plasma induced by the interaction of hypervelocity moving structural/material systems with the atmosphere. The motivation for this effort originates from the need to compute the radiative heat fluxes imparted to hypersonic vehicles to facilitate their design, control, and maintenance. In response to this need, a computational framework was established to predict the fluid dynamics fields around a hypervelocity vehicle that in turn is coupled with the plasma physics that enables the calculation of the plasma fields and species dynamics. This framework implements a one-way coupling between fluid dynamics and plasma physics models. The framework solves the fluid dynamics partial differential equations representing the conservation of mass, momentum, and energy. The computed pressure, velocity, and temperature fields are subsequently utilized to drive the plasma physics PDEs describing the mass transport and energetics of all the nitrogen-oxygen 11 species present according to the so-called Dunn plasma model. An application of this framework for a spherical body for a wide range of velocities is presented as a verification of the framework’s functionality. Typical distributions of the fluid and plasma dynamics are presented. Finally, the plasma radiance spectra are produced by employing statistical mechanics principles. © 2024 by The United States Government.

关键词： Statistical mechanics

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DATA–DEFINED MACHINE INTELLIGENCE FOR MECHANICAL PROPERTIES IDENTIFICATION

DATA–DEFINED MACHINE INTELLIGENCE FOR MECHANICAL PROPERTIES...

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ASME 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2024

作者： Iliopoulos, A.P. Michopoulos, J.G. Steuben, J.C. Apetre, N. Computational Multiphysics Systems Laboratory Materials Science and Technology Division U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791888353

In this work we are introducing a Machine Intelligence (MI) concept that belongs to the set of approaches that emphasize data over artificial intelligence model. The development of the concept was motivated by the need to eliminate training as the means to enable fast or perpetual system adaptation and update, and also vastly reduce pre-processing times. This characteristic can be extremely valuable in situations when new data are regularly becoming available and utilized to increase the MI accuracy with minimal delay, or when the represented system changes with time. A characteristic of the proposed data–defined MI approach is that of introspection;it can be queried to locally estimate the system error at any data point that is part of its data set and potentially act accordingly. To provide evidence of the validity and performance of the approach, we first demonstrate on classical hand-writing classification of numerical digits. We then apply it to a challenging problem of identifying the properties of bi-linear elastoplastic material using a single full-field strain tensor image of a synthetic experiment. The validation test is performed for many untrained instances, and the histogram, mean and maximum errors are discussed. We also discuss several interesting capabilities that a data–defined concept enables. Copyright © 2024 by The United States Government.

关键词： Tensors

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Multiscale tomographic wave-matter interaction modeling to enable artifact-free material defect reconstruction

Multiscale tomographic wave-matter interaction modeling to e...

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ASME 2020 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2020

作者： Steuben, J.C. Michopoulos, J.G. Iliopoulos, A.P. Graber, B.D. Birnbaum, A.J. Computational Multiphysics Systems Laboratory Center of Materials Physics and Technology U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791883983

The fabrication and subsequent in-service excitation of materials/structures invariably generates significant defects including cracks, voids and inclusions, spanning many length scales. The various technologies available for detecting and qualitatively describing such defects suffer from the introduction of various degrees inaccuracy when it comes to the quantification of defect geometry. This can have an adverse impact on modeling and understanding how the material/part/structure performance is effected by these defects. The main cause of this shortcoming is that aspects of the physical processes used to interrogate the material system, using monochromatic or polychromatic waves such as X-ray, mm-wave, or ultrasound, are not taken into account. These waves interact with the multiscale defect ensemble in a complex fashion that inevitably produces spurious "artifacts" in the resulting data, which cannot be removed via conventional data post-processing. These artifacts then introduce unacceptable levels of error when reconstructing defect geometry and computing the remaining lifespan of defect-bearing materials/structures. The present work introduces preliminary efforts towards a multiscale modeling and simulation framework for capturing the interactions of waves (such as X-rays) with materials bearing defect ensembles. It is shown that conventional approaches such as ray tracing are not adequate, and a more robust solution to the relevant wave equations utilizing the Finite Element discretization is employed. A general parameterization of defect geometries based on superquadratic functions is also introduced, and the interactions of defects modeled in this fashion with X-rays are investigated. It is also shown that this combination of parameterization and modeling techniques allows the recovery of true, artifact-free defect geometry utilizing classical inverse methods. The methodology is demonstrated using synthetic tomographic data, and the path forward to a more c

关键词： Wave equations

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GENERALIZED ANISOTROPIC MULTIOBJECTIVE TOPOLOGY OPTIMIZATION FOR NAVAL ADDITIVE MANUFACTURING

GENERALIZED ANISOTROPIC MULTIOBJECTIVE TOPOLOGY OPTIMIZATION...

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ASME 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2024

作者： Steuben, J.C. Iliopoulos, A.P. Birnbaum, A.J. Graber, B.D. Michopoulos, J.G. Computational Multiphysics Systems Laboratory Materials Science and Technology Division U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791888346

The use of topology optimization algorithms for engineering design has become widespread. Motivated by the objective of producing lightweight, high-performance components, a wide variety of approaches have emerged, and many alternatives now exist for every stage of the associated computing pipeline. The present work introduces a generalized topology optimization framework for use in the area of additive manufacturing (AM), with a focus on naval applications. The development of this framework is outlined, with particular attention paid to the development of an anisotropic experimental data-driven material constitutive model. Additionally, methods for handling arbitrary numbers of objectives, design constraints imposed by additive manufacturing process physics, and boundary conditions particular to naval applications are explored. Steps for post-processing and refining the optimizer output in order to produce manufacturing-ready files are also discussed. The approach is demonstrated on a pair of test cases. The first is the design of an optimized "conformal" pressure vessel, which departs from the typical sphere / cylinder forms and allows for increased storage capacity by occupying a non-convex envelope space. The second application problem is the design of an optimized propulsor intended to be produced using large-scale AM. This propulsor is optimized for inertial and hydrodynamic loads, and a parametric study of the effect of outer shell thickness is performed. © 2024 by The United States Government.

关键词： Shape optimization

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TOWARDS A multiphysics-BASED DIGITAL TWIN FOR PREDICTING AGING OF MULTIMATERIAL ADHESIVE STEP LAP JOINTS

TOWARDS A MULTIPHYSICS-BASED DIGITAL TWIN FOR PREDICTING AGI...

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ASME 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2024

作者： Michopoulos, J.G. Apetre, N.A. Iliopoulos, A.P. Steuben, J.C. Computational Multiphysics Systems Laboratory Materials Science and Technology Division U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791888346

We present the initial steps towards formulating a multiphysics-based digital twin for predicting aging for multi-material adhesive step lap joints (ASLJs) that accounts for mechanical and environmental generalized loading. Initially, we provide a definition of the digital twin context and the particular digital twin architecture considered associated with the data-driven digital twin flavor. Subsequently, focus is given to establishing and exercising a theoretical and computational framework accounting for the degradation of properties for materials participating in ASLJs due to environmentally-aided damage accumulation. A thermodynamics-based theory is derived as a first step. An initial computational implementation of it is developed and applied to two models of multi-material ASLJs involving a titanium Ti-6Al4V alloy and carbon epoxy composite adherent and an FM-300K adhesive. Several studies have been performed to identify the effect of parameters related to the choice of element order, mesh density, damage parameters and inclusion of damage models for the participating domains. Finally, the predictions obtained from the framework are compared with experimental results to establish the necessary validation for two environmental conditions of room and elevated temperatures at low ambient humidity. These results provide an initial insight into the characteristics of the aging degradation of ASLJ performance when both the adhesive and the composite material adherent are accumulating damage and contribute to aging of the respective materials. © 2024 by The United States Government.

关键词： Titanium alloys

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Generation of continuous toolpaths for additive manufacturing using implicit slicing 41

Generation of continuous toolpaths for additive manufacturin...

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41st Computers and Information in Engineering Conference, CIE 2021, Held as Part of the ASME 2021 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2021

作者： Steuben, J.C. Michopoulos, J.G. Iliopoulos, A.P. Computational Multiphysics Systems Laboratory Center of Materials Physics and Technology U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791885376

The generation of toolpaths for additive manufacturing (AM), a process commonly known as "slicing," has a strong impact on the performance of both the associated hardware systems and the resulting objects. Available slicers invariably produce discontinuous toolpaths, featuring jumps or so-called "travel moves" during which the deposition of material or/and energy must be halted. For AM processes using slowly solidifying feedstock materials, such as thermosetting polymers or cementitious mixtures such as concrete, these toolpath discontinuities are highly undesirable due to the artifacts they generate. This renders existing slicers difficult to use in such applications, and presents a roadblock to the adoption of AM for such material systems. In the present work, this difficulty is addressed by the development of a simple geometric criterion for the existence of continuous toolpaths that are capable of producing a specified input geometry. This development is based on the principles of morphological geometric analysis and graph theory. It is shown that, for any geometric feature with a characteristic thickness at least twice the extrusion width, a continuous toolpath exists. Furthermore, a general-purpose algorithm for continuous toolpath generation, for arbitrarily shaped objects satisfying this criterion, is developed and demonstrated on a representative test problem. Finally, conclusions and the path forward for the usage of this approach with existing AM systems is explored. Copyright © 2021 by ASME and The United States Government

关键词： 3D printers

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OBJECTIVE COLORMAPS FOR MINIMIZING INTERPRETATION BIAS IN SCIENCE AND ENGINEERING

OBJECTIVE COLORMAPS FOR MINIMIZING INTERPRETATION BIAS IN SC...

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ASME 2024 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2024

作者： Iliopoulos, A.P. Michopoulos, J.G. Steuben, J.C. Apetre, N. Birnbaum, A. Computational Multiphysics Systems Laboratory Materials Science and Technology Division U.S. Naval Research Laboratory WashingtonDC20375 United States

ISBN: (纸本)9780791888346

While working on the implementation of hygro-thermo-structural models for composite materials like those used in aircraft, we started noticing discontinuities in the fringe plots of the validation tests. This led us down a time-consuming path of debugging the implementation, that indicated that there were no problems with our numerical code. After further investigation we established the the issue emanated from the non-uniform nature of the colormap used to map the field variables. In researching the matter further we identified several contemporary attempts in establishing metric to judge the perceptual non-uniformity of colormaps. In this work we extend these attempts to encompass objective functions that allow for the automated generation of colormaps that minimize non-uniformity with the goal to reduce visual bias to the extent allowed by modern color theory and color standards. The objective functions are formulates on the basis of lightness, chromaticity, gamut completion, and desired color in both explicit and implict forms. We present several application examples and illustrate them based on typical benchmark data. We furthermore demonstrate the appearance of colormaps for the three types of color vision deficiency using simulated mapping. These studies are a precursor of refinement of the proposed framework towards more universal colormaps. © 2024 by The United States Government.

关键词： Aircraft materials

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Multi-level coupling of dynamic data-driven experimentation with material identification

Multi-level coupling of dynamic data-driven experimentation ...

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7th International Conference on computational Science (ICCS 2007)

作者： Michopoulos, John G. Furukawa, Tomonari Computational Multiphysics Systems Laboratory Center for Computational Material Science Special Projects Group United States ARC Centre of Excellence in Autonomous Systems School of Mechanical and Manufacturing Engineering J17 The University of New South Wales Sydney NSW 2052 Australia

ISBN: (纸本)9783540725831

We describe a dynamic data-driven methodology that is capable of simultaneously determining both the parameters of a constitutive model associated with the response of a composite material, and the optimum experimental design that leads to the corresponding material characterization. The optimum design of experiments may contain two parts. One involving the identification of the parameters that are tunable prior to performing the experiment such as specimen characteristics and a priori loading path. The other is involving the parameters characterizing the experiment during the experiment itself such as the directionality of the loading path for the case of multi-axial loading machine. A multi-level coupled design optimization methodology is developed and applied to demonstrate the concept. Essential to the process is the development of objective functions that express the quality of the experimental procedure in terms of the uniqueness and distinguishability associated with the inverse solution of the constitutive model determination. The examples provided are based on the determination of the linear constitutive response of a laminate composite material.

关键词： Data structures

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computational parameterization simplicity and filtering of data-driven inverse analysis for heat deposition processes

Computational parameterization simplicity and filtering of d...

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2006 ASME International Design Engineering Technical Conferences and Computers and Information In Engineering Conference, DETC2006

作者： Lambrakos, S.G. Michopoulos, J.G. Code 6390 Center for Computational Material Science Naval Research Laboratory Washington DC 20375 United States Computational Multiphysics Systems Lab. Special Projects Group Center for Computational Material Science Washington DC 20375 United States

ISBN: (纸本)079183784X

This paper underscores two important computational aspects associated with algorithms for data-driven inverse analysis and characterization of heat deposition processes. The first involves the fact that the mathematical foundation of these algorithms suggests that a very large class of temperature fields, associated with different types of heat deposition processes and different domain geometries can be represented parametrically by a relatively small set of functions. They include linear combinations of solutions to the heat conduction equation. Issues concerning the use of algorithms based on different types of parametric representations related to different types of heat deposition processes are discussed. A prototype analysis is presented to demonstrate many characteristics of these algorithms that are significant for their practical application. The second aspect relates to the filtering property of inversion itself due to the nature of the kernel function involved with the description of the heat source. Both of these aspects are crucially beneficial to developing methodologies that effect the real-time dynamic data-driven production parameter adjustments of manufacturing processes involving heat deposition. Copyright © 2006 by ASME.

关键词： computational geometry

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