Speaker
Description
Topology optimization enables the development of lightweight and high-performance components, although the resulting complex geometries are often difficult to manufacture using conventional methods. Wire Arc Additive Manufacturing (WAAM) provides an effective solution due to its high deposition rate, material efficiency, and capability to fabricate large metallic structures. However, the thermal history during WAAM significantly affects temperature distribution, residual stresses, distortion, and component quality. This study presents an integrated computational framework combining Solid Isotropic Material with Penalization (SIMP)-based topology optimization, transient thermal finite element analysis, and process parameter optimization for WAAM. Topology optimization was performed in Tosca Structure to minimize structural volume while satisfying stress constraints, and the optimal design was selected using multi-criteria decision analysis. The selected geometry was analyzed in Abaqus using Goldak's double-ellipsoidal heat source model to simulate thermal evolution during WAAM. Layer height and heat source parameters were optimized using the Evolutionary Optimization Algorithm in Isight, and the optimized model was evaluated at deposition travel speeds of 480, 600, and 750 mm/min. Increasing travel speed reduced peak temperatures and reheating cycles, improving thermal stability. The proposed framework provides a systematic design-to-manufacturing approach for producing lightweight WAAM-fabricated metallic components with enhanced manufacturability and process reliability.
| Topic Area | Design Optimization, Additive Manufacturing Technologies & Applications |
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