Topological optimization of structures with thermomechanical loading under compliance constraints for 3D printing applications

Currently, due to the high costs of production and expensive raw materials, approaches, including, making models smaller and lighter, are especially considered in the design of structures. In order to better describe the capabilities, efficiency, and limitations of an innovative field called topology optimization, various practical problems under different loadings and boundary conditions were evaluated in this study. Optimization algorithms were used in ANSYS software for the optimization of a cantilever beam under static loading, double-girder beam and a dome-shaped geometry under static and thermal loading, a hot fluid transfer tee and an engine exhaust manifold under static loading and convection heat transfer. The results showed that the reduced volume in the final models were equal to 66.29%, 52.88%, 50.05%, 51.85%, and 35.02%, respectively. Consequently, this reduced volume causes some increase in the tension, and displacement of the final model, which can adjust them according to the limitations governing the problem. Furthermore, the amount of increase in the average value of the stress in the cantilever beam, double-girder beam, and dome-shaped geometry were 88, 800, and 6 MPa, and the average amount of displacement in these samples increased by 10.2%, 200%, and 3.3%, respectively. Challenges, and manufacturability of optimized problems were investigated by 3D printing of a dome-shaped model using the FDM method, which illustrated that the output product has a suitable level of accuracy and smoothness. Subsequently, by using supporting structures, three-dimensional holes were created with proper precision in the 3D-printed sample, which satisfied the manufacturability of relatively complex models.