Properties Evaluations of Topology Optimized Functionally Graded Lattice Structures Fabricated by Selective Laser Melting

Abstract

Owning to their lightweight characteristic and high performance, functionally graded lattice structures (FGLSs) show great potential in orthopedics, automotive industries and aerospace applications. Here, two types of uniform lattice structures (ULSs) with RD = 0.50 and 0.20, and two types of FGLSs with RD = 0.30–0.50 and RD = 0.20–0.40, were designed by topology optimization and fabricated by SLM technology. Subsequently, their surface morphology, compressive deformation behavior and energy absorption abilities were evaluated by use of the finite element method (FEM) and compression tests. From these results, both elastic modulus and yield strength of specimens decreased with the lowering of the RD value. ULSs had a uniform deformation behavior with bending and bulking of struts, while FGLSs presented a mixed deformation behavior of different layers. Additionally, the energy absorption capability (Wv) of specimens was proportional to the RD value. When the value of RD increased from 0.20 to 0.50, the Wv of specimens increased from 0.3657 to 1.7469 MJ/m3. Furthermore, mathematical models were established successfully to predict the mechanical properties of FGLSs with percentage deviations < 10%. This work provides a comprehensive understanding regarding how to design and manufacture FGLSs with the properties desired for satisfying the demand of different application scenarios.

Keywords

• topology optimization
• functionally graded lattice structures
• selective laser melting
• 316L stainless steel