连续纤维增强复合材料结构拓扑优化设计与3D打印

TOPOLOGICAL OPTIMIZATION DESIGN AND 3D PRINTING OF CONTINUOUS FIBER REINFORCED COMPOSITE STRUCTURES

  • 摘要: 连续纤维增强复合材料(Continuous Fiber Reinforced Composite, CFRC)因其高强度、轻量化及可设计的特性,已成为高端装备的关键材料。深度融合拓扑优化与增材制造技术,充分发挥纤维增强复合材料的可设计性与3D打印的高制造灵活性,是实现高性能CFRC构件设计-制造一体化的一种有效途径。本文基于浮动映射拓扑优化(Floating Projection Topology Optimization, FPTO)方法,对纤维增强复合材料(CFRC)结构构型与材料方向进行一体化设计;运用平面流场理论,构建力流场与连续纤维场误差函数,拟合生成光滑、无交叉的连续纤维铺设轨迹;采用贪心算法规划连续纤维3D打印路径,满足打印工艺要求的同时,减少打印空行程;最后,基于熔丝堆积(Fused Filament Fabrication, FFF)和连续纤维共挤(Composite Fiber Co-extrusion, CFC)3D打印技术,实现拓扑优化构件曲线连续增强纤维沿受力路径精确打印制造,通过打印及测试结果,验证本文方法的可行性和有效性,该方法可为高性能纤维增强复合材料结构的创新设计与快速制造提供一种有效解决方案。

     

    Abstract: Continuous fiber reinforced composite (CFRC) has become a key material for high-end equipment due to its high strength, lightweight, and designability. The deep integration of topology optimization and of additive manufacturing technology, fully leveraging the designability of fiber-reinforced composite materials and the high manufacturing flexibility of 3D printing, is a key approach for designing and manufacturing high-performance CFRC structures. In this article, the structural configuration and material orientation of fiber-reinforced composite materials is optimized concurrently based on the floating projection topology optimization (FPTO) method. And then smooth and non-crossing continuous fiber printing trajectories are successfully fitted and generated by constructing an error function for force flow field and continuous fiber field using the theory of planar fluids. Greedy algorithm is adopted to plan the continuous fiber 3D printing path, while meeting the printing process requirements and reducing the printing stroke. Finally, based on fused filament fabrication (FFF) and continuous fiber co-extrusion (CFC) 3D printing technology, the obtained structures through topology optimization are manufactured where the curved and continuous reinforced fibers are accurately printed along the load transfer path. The feasibility and effectiveness of the method proposed are validated through printing and testing results. The approach proposed offers an effective solution for innovative design and for rapid manufacturing of high-performance fiber-reinforced composite structures.

     

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