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Parametric Shape Optimization for Combined Additive–Subtractive Manufacturing

  • ICME-Based Design and Optimization of Materials for Additive Manufacturing
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Abstract

In industrial practice, additive manufacturing (AM) processes are often followed by post-processing operations such as heat treatment, subtractive machining, milling, etc., to achieve the desired surface quality and dimensional accuracy. Hence, a given part must be 3D-printed with extra material to enable this finishing phase. This combined additive/subtractive technique can be optimized to reduce manufacturing costs by saving printing time and reducing material and energy usage. In this work, a numerical methodology based on parametric shape optimization is proposed for optimizing the thickness of the extra material, allowing for minimal machining operations while ensuring the finishing requirements. Moreover, the proposed approach is complemented by a novel algorithm for generating inner structures to reduce the part distortion and its weight. The computational effort induced by classical constrained optimization methods is alleviated by replacing both the objective and constraint functions by their sparse grid surrogates. Numerical results showcase the effectiveness of the proposed approach.

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Acknowledgements

This work was funded by the European Union’s Horizon 2020 research and innovation program under Grant Agreement No. 680,448 CAxMan, Computer-Aided technologies for Additive Manufacturing.

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Authors and Affiliations

  1. Consiglio Nazionale Delle Ricerche, Istituto di Matematica Applicata e Tecnologie Informatiche (CNR-IMATI), Pavia, Italy

    Lorenzo Tamellini, Federico Marini & Massimiliano Martinelli

  2. International Center for Numerical Methods in Engineering (CIMNE), Universidad Politécnica de Cataluña, Barcelona, Spain

    Michele Chiumenti

  3. Fraunhofer Institute for Computer Graphics Research IGD, Interactive Engineering Technologies, Darmstadt, Germany

    Christian Altenhofen

  4. Interactive Graphics Systems Group, Technische Universität Darmstadt, Darmstadt, Germany

    Christian Altenhofen

  5. Consiglio Nazionale Delle Ricerche, Istituto di Matematica Applicata e Tecnologie Informatiche (CNR-IMATI), Genova, Italy

    Marco Attene & Marco Livesu

  6. SINTEF Digital, Mathematics and Cybernetics, Oslo, Norway

    Oliver Barrowclough & Vibeke Skytt

Authors
  1. Lorenzo Tamellini
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  2. Michele Chiumenti
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  3. Christian Altenhofen
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  4. Marco Attene
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  5. Oliver Barrowclough
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  6. Marco Livesu
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  7. Federico Marini
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  8. Massimiliano Martinelli
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  9. Vibeke Skytt
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Correspondence to Lorenzo Tamellini.

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Tamellini, L., Chiumenti, M., Altenhofen, C. et al. Parametric Shape Optimization for Combined Additive–Subtractive Manufacturing. JOM 72, 448–457 (2020). https://doi.org/10.1007/s11837-019-03886-x

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  • DOI: https://doi.org/10.1007/s11837-019-03886-x

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