Investigation on the modelling approach for variable-density lattice structures fabricated using selective laser melting

Jun Song; Qian Tang; Qixiang Feng; Shuai Ma; Fuyu Guo; Quanquan Han

Materials & Design (Dec 2021)

Investigation on the modelling approach for variable-density lattice structures fabricated using selective laser melting

Jun Song,
Qian Tang,
Qixiang Feng,
Shuai Ma,
Fuyu Guo,
Quanquan Han

Affiliations

Jun Song: State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
Qian Tang: State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
Qixiang Feng: State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China; State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027, China; Corresponding author: No. 174, Shazheng Street, Shapingba District, Chongqing 400044, China.
Shuai Ma: State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
Fuyu Guo: State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
Quanquan Han: Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Centre for Additive Manufacturing, School of Mechanical Engineering, Shandong University, Jinan 250061, China

Journal volume & issue: Vol. 212
p. 110236

Abstract

Read online

Selective laser melting (SLM)-produced variable-density (VD) lattice structures are deemed a promising solution to lightweight design. However, due to the large number of cells in the structures, designing VD structures is still time-consuming and exhibits poor adaptability to external load. Therefore, in order to decrease the number of design variables in VD design, this paper proposed a modelling approach for VD lattice structures manufactured using SLM. The stress values provided by finite element analysis (FEA) were grouped according to k-means clustering, where the sizes of lattice cells in the same group remain identical. Then the relative densities of cells’ in all groups are obtained and the VD model is generated. By taking the design of a VD lattice beam as an example, the feasibility of the proposed method was verified by conducting FEA and three-point bending tests on SLM-produced Ti6Al4V samples, as well as using morphological observation measures. The results show that the number of design variables for reconstructing the beam was decreased from 125 to 8, and the VD samples reached the designed carrying capacity and also presented superior lightweight performance compared with their isovolumetric homogenous counterparts.

Published in Materials & Design

ISSN: 0264-1275 (Print); 1873-4197 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering: Materials of engineering and construction. Mechanics of materials
Website: https://www.journals.elsevier.com/materials-and-design

About the journal

Abstract

Keywords