Fatigue Behavior of Metallic Components Obtained by Topology Optimization for Additive Manufacturing

Felipe Fiorentin; Bernardo Oliveira; João Pereira; José Correia; Abilio M.P. de Jesus; Filippo Berto

doi:10.3221/IGF-ESIS.55.09

Authors

F.K. Fiorentin INEGI/Faculty of Engineering, University of Porto, Portugal
B. Oliveira INEGI/Faculty of Engineering, University of Porto, Portugal
J.C.R. Pereira INEGI/Faculty of Engineering, University of Porto, Portugal
J.A.F.O. Correia INEGI/Faculty of Engineering, University of Porto, Portugal
Abilio M.P. de Jesus INEGI/Faculty of Engineering, University of Porto, Portugal http://orcid.org/0000-0002-1059-715X
F. Berto NTNU - Norwegian University of Science and Technology, Norway

DOI:

https://doi.org/10.3221/IGF-ESIS.55.09

Keywords:

Metallic Additive Manufacturing, Topology Optimization, Building Strategy, Residual Stress, Fatigue Life Prediction, Multiaxial Criterion

Abstract

The main goal of the present research is to propose an integrated methodology to address the fatigue performance of topology optimized components, produced by additive manufacturing. The main steps of the component design will be presented, specially the methods and parameters applied to the topology optimization and the post-smoothing process. The SIMP method was applied in order to obtain a lighter component and a suitable stiffness for the desired application. In addition, since residual stresses are intrinsic to every metallic additive manufacturing process, the influence of those stresses will be also analyzed. The Laser Powder Bed Fusion was numerically simulated aiming at evaluating the residual stresses the workpiece during the manufacturing process and to investigate how they could influence the fatigue behavior of the optimized component. The effect of the built orientation of the workpiece on the residual stresses at some selected potential critical points are evaluated. The final design solution presented a stiffness/volume ratio nearly 6 times higher when compared to the initial geometry. By choosing the built orientation, it is possible impact favorably in the fatigue life of the component.

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Author Biographies

F.K. Fiorentin, INEGI/Faculty of Engineering, University of Porto, Portugal

PhD Student at FEUP
B. Oliveira, INEGI/Faculty of Engineering, University of Porto, Portugal

MSc
J.C.R. Pereira, INEGI/Faculty of Engineering, University of Porto, Portugal

Post-doc researcher at INEGI
J.A.F.O. Correia, INEGI/Faculty of Engineering, University of Porto, Portugal

Junior PhD researcher at FEUP
Abilio M.P. de Jesus, INEGI/Faculty of Engineering, University of Porto, Portugal

Abílio Manuel Pinho de Jesus, born in 1973 in Oliveira de Azeméis, Portugal, is Auxiliary Professor at the Department of Mechanical Engineering of the Faculty of Engineering from the University of Porto (FEUP) since 2014, after 18 years of teaching activity at the Department of Engineering of the University of Trás-os-Montes e Alto Douro, Vila Real, Portugal. He is also research member at the Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI) and is integrated in the Associated Laboratory for Energy, Transports and Aeronautics (LAETA). He obtained the BSc (1996) and MSc (1999) degrees in Mechanical Engineering by the University of Porto and the PhD in Mechanical Engineering by the University of Trás-os-Montes e Alto Douro in 2004. He is co-author of more than 120 papers in the national and international scientific journals and more than 200 papers presented in both national and international conferences. A total of 120 documents in SCOPUS and an h-index of 16 show the consistency and visibility of the research work that has been developed in the fields of fatigue and fracture of materials and structures. The recent edition of the Structural Integrity Book series, the nomination for the ESIS TC12 and the new European Project, FASTCOLD, highlights the research excellency being performed. The manufacturing processes, and particularly machining processes, have been recently elected as a research priority; the grounds of a group in the field are being created. Process simulation, material characterization, hybrid manufacturing (additive and subtractive) and composites machining are targeted.