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DESIGN METHOD FOR CONFORMAL LATTICE-SKIN STRUCTURE FABRICATED BY AM TECHNOLOGIES

机译：AM技术制造的保形晶格皮结构的设计方法

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Parts with complex geometry can be produced by additive manufacturing processes without a significant increase in fabrication time and cost. One application of AM technologies is to fabricate customized lattice-skin structures which can enhance the functional performance of products with less material and less weight. In this paper, a brief comparison between different types of lattice structures and their related design methods has been done. The result shows that conformal lattice structures may perform better than other types of lattice due to its unique configuration for some design cases. However, most existing design methods of conformal lattice have a limitation to deal with complex external geometry. To solve this issue and fully utilize conformal lattice structures, a general design method for a conformal lattice-skin structure is proposed. This design method consists of two major design stages. At the beginning design stage, conformal surfaces are selected based on proposed general design guidelines. Then two different lattice frame generation methods are provided to generate conformal lattice to fit the selected conformal surfaces. A comparison between these two methods is made to help designers select a suitable method for their design cases. In the second design stage, the thickness of each lattice strut is calculated based on a defined mapping function. This mapping function generally considers two important factors from the result of topology optimization. They are optimal relative density distribution and its related principle stress direction. Based on the calculated strut's thickness, the geometry model of heterogeneous conformal lattice can be generated. At the end of the design process, skin structures can be added on the generated heterogeneous conformal lattice. To further illustrate and validate the proposed design method, a design case of handle connector is provided. The result of this case study shows this method can provide an efficient tool for designers to generate the conformal lattice-skin structure for a complex external shape.
机译：具有复杂几何形状的零件可以通过添加制造工艺生产，而没有显着增加制造时间和成本。 AM技术的一种应用是制造定制的晶格性皮肤结构，可以提高产品的功能性能，更少的产品和更小的重量。本文已经完成了不同类型的晶格结构与其相关设计方法的简要比较。结果表明，由于其独特的配置案例，保形晶格结构可以比其他类型的晶格更好地执行。然而，最现有的保形晶格的设计方法有限制处理复杂的外部几何形状。为了解决这个问题并充分利用保形晶格结构，提出了一种用于保形晶格 - 皮肤结构的一般设计方法。这种设计方法包括两个主要的设计阶段。在开始设计阶段，基于所提出的一般设计指南选择共形表面。然后提供两种不同的晶格帧生成方法以产生适形格子以适合所选择的共形表面。这两种方法之间的比较是为了帮助设计人员为其设计案例选择合适的方法。在第二设计阶段，基于定义的映射函数计算每个晶格Strut的厚度。该映射功能通常考虑拓扑优化结果的两个重要因素。它们是最佳的相对密度分布及其相关原理应力方向。基于计算的支柱的厚度，可以产生异构保形晶格的几何模型。在设计过程结束时，可以在产生的异构保形晶格中添加皮肤结构。为了进一步说明和验证所提出的设计方法，提供了手柄连接器的设计案例。本案例研究的结果表明，该方法可以为设计者提供有效的工具，以产生复杂的外部形状的保形晶格 - 皮肤结构。

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