Additive manufacturing-driven simultaneous optimization of topology and print direction for thermoelastic structures considering strength failure

Abstract This paper presents a strength-based simultaneous optimization method for optimizing thermoelastic structural topology and print direction in the presence of anisotropy induced by additive manufacturing. The approach utilizes the bi-directional evolutionary structural optimization framework and defines design variables including element density and print-off angle. Firstly, an anisotropic thermoelastic constitutive model is established for finite element analysis. By introducing the Tsai–Hill failure criteria, the strength constraint to evaluate the stress level of additively manufactured anisotropic components is formulated. The P-norm aggregation function is employed to approximate the maximum strength failure coefficient. Then, the aggregated strength constraint is augmented to the optimization objective through a Lagrange multiplier. Sensitivity analysis of the new objective function with respect to the elemental design variables is performed, and an analytical approach is proposed to optimize the print-off angle. To improve the stability of the optimization procedure, a series of numerical algorithms and parameter updating strategies are developed. The effectiveness of our proposed method is demonstrated through typical numerical examples, highlighting a desirable match between the structural topology and the print direction can greatly improve the structural performance.