TY - JOUR
T1 - Optimized design and additive manufacture of double-sided metal mirror with self-supporting lattice structure
AU - Yang, Ding
AU - Pan, Chen
AU - Zhou, Yong
AU - Han, Yafeng
N1 - Publisher Copyright:
© 2022
PY - 2022/7
Y1 - 2022/7
N2 - Lattice structure has excellent mechanical properties to develop lightweight devices, and additive manufacture makes it possible to construct complex lattice without extra cost. Especially, with the development of structural optimization technology, design of gradient lattice structure with optimized material distribution has become a research hotspot. In this paper, a double-sided metal mirror infilled with topology optimization (TO) based self-supporting lattice structure and fabricated with selective laser melting (SLM) was proposed. Considering the manufacturing constraints of SLM technology, commonly used body-centered cubic (BCC) lattice was modified and coordinate transformed to construct the self-supporting infill of the mirror. To further improve the mechanical properties of the structure, density-based TO method was introduced to optimize the diameters of all struts in the infill lattice. Finally, an SLM 3D printer was utilized to manufacture the mirror, and both stiffness and anti-vibration performance of the original and two different lattice infilled metal mirrors were evaluated through FEA. Compression tests were also conducted to verify the compressive property of all mirrors. Even though with 20% less material cost, both computational and experimental verifications have shown that the optimized lattice infilled mirror has much better mechanical properties compared with the original design.
AB - Lattice structure has excellent mechanical properties to develop lightweight devices, and additive manufacture makes it possible to construct complex lattice without extra cost. Especially, with the development of structural optimization technology, design of gradient lattice structure with optimized material distribution has become a research hotspot. In this paper, a double-sided metal mirror infilled with topology optimization (TO) based self-supporting lattice structure and fabricated with selective laser melting (SLM) was proposed. Considering the manufacturing constraints of SLM technology, commonly used body-centered cubic (BCC) lattice was modified and coordinate transformed to construct the self-supporting infill of the mirror. To further improve the mechanical properties of the structure, density-based TO method was introduced to optimize the diameters of all struts in the infill lattice. Finally, an SLM 3D printer was utilized to manufacture the mirror, and both stiffness and anti-vibration performance of the original and two different lattice infilled metal mirrors were evaluated through FEA. Compression tests were also conducted to verify the compressive property of all mirrors. Even though with 20% less material cost, both computational and experimental verifications have shown that the optimized lattice infilled mirror has much better mechanical properties compared with the original design.
KW - Additive manufacture
KW - Lattice structure
KW - Lightweight metal mirror
KW - Self-supporting
KW - Topology optimization
UR - http://www.scopus.com/inward/record.url?scp=85130821703&partnerID=8YFLogxK
U2 - 10.1016/j.matdes.2022.110759
DO - 10.1016/j.matdes.2022.110759
M3 - Article
AN - SCOPUS:85130821703
SN - 0264-1275
VL - 219
JO - Materials and Design
JF - Materials and Design
M1 - 110759
ER -