Joshua Robbins

Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation

Purpose The purpose of the paper is to propose a homogenization-based topology optimization method to optimize the design of variable-density cellular structure, in order to achieve lightweight design and overcome some of the manufacturability issues in additive manufacturing. Design/methodology/approach First, homogenization is performed to capture the effective mechanical properties of cellular structures through the scaling law as a function their relative density. Second, the scaling law is used directly in the topology optimization algorithm to compute the optimal density distribution for the part being optimized. Third, a new technique is presented to reconstruct the computer-aided design (CAD) model of the optimal variable-density cellular structure. The proposed method is validated by comparing the results obtained through homogenized model, full-scale simulation and experimentally testing the optimized parts after being additive manufactured. Findings The test examples demonstrate that the homogenization-based method is efficient, accurate and is able to produce manufacturable designs. Originality/value The optimized designs in our examples also show significant increase in stiffness and strength when compared to the original designs with identical overall weight.

ALEGRA : version 4.6.

ALEGRA is an arbitrary Lagrangian-Eulerian multi-material finite element code used for modeling solid dynamics problems involving large distortion and shock propagation. This document describes the basic user input language and instructions for using the software.

ALEGRA: User Input and Physics Descriptions Version 4.2

ALEGRA is an arbitrary Lagrangian-Eulerian finite element code that emphasizes large distortion and shock propagation. This document describes the user input language for the code.

Ductile failure X-prize.

Fracture or tearing of ductile metals is a pervasive engineering concern, yet accurate prediction of the critical conditions of fracture remains elusive. Sandia National Laboratories has been developing and implementing several new modeling methodologies to address problems in fracture, including both new physical models and new numerical schemes. The present study provides a double-blind quantitative assessment of several computational capabilities including tearing parameters embedded in a conventional finite element code, localization elements, extended finite elements (XFEM), and peridynamics. For this assessment, each of four teams reported blind predictions for three challenge problems spanning crack initiation and crack propagation. After predictions had been reported, the predictions were compared to experimentally observed behavior. The metal alloys for these three problems were aluminum alloy 2024-T3 and precipitation hardened stainless steel PH13-8Mo H950. The predictive accuracies of the various methods are demonstrated, and the potential sources of error are discussed.

Microstructural modeling of ferroic switching and phase transitions in PZT.

Niobium doped Lead Zirconate Titanate (PZT) with a Zr/Ti ratio of 95/5 (i.e., PZT 95/5-2Nb) is a ferroelectric with a rhombohedral structure at room temperature. A crystal (or a subdomain within a crystal) exhibits a spontaneous polarization in any one of eight crystallographically equivalent directions. Such a material becomes polarized when subjected to a large electric field. When the electric field is removed, a remanent polarization remains and a bound charge is stored. A displacive phase transition from a rhombohedral ferroelectric phase to an orthorhombic anti-ferroelectric phase can be induced with the application of a mechanical load. When this occurs, the material becomes depoled and the bound charge is released. The polycrystalline character of PZT 95/5-2Nb leads to highly non-uniform fields at the grain scale. These local fields lead to very complex material behavior during mechanical depoling that has important implications to device design and performance. This paper presents a microstructurally based numerical model that describes the 3D non-linear behavior of ferroelectric ceramics. The model resolves the structure of polycrystals directly in the topology of the problem domain and uses the extended finite element method (X-FEM) to solve the governing equations of electromechanics. The material response is computed from anisotropic single crystal constants and the volume fractions of the various polarization variants (i.e., three variants for rhombohedral anti-ferroelectric and eight for rhomobohedral ferroelectric ceramic). Evolution of the variant volume fractions is governed by the minimization of internally stored energy and accounts for ferroelectric and ferroelastic domain switching and phase transitions in response to the applied loads. The developed model is used to examine hydrostatic depoling in PZT 95/5-2Nb.

LDRD final report : mesoscale modeling of dynamic loading of heterogeneous materials.

Material response to dynamic loading is often dominated by microstructure (grain structure, porosity, inclusions, defects). An example critically important to Sandias mission is dynamic strength of polycrystalline metals where heterogeneities lead to localization of deformation and loss of shear strength. Microstructural effects are of broad importance to the scientific community and several institutions within DoD and DOE; however, current models rely on inaccurate assumptions about mechanisms at the sub-continuum or mesoscale. Consequently, there is a critical need for accurate and robust methods for modeling heterogeneous material response at this lower length scale. This report summarizes work performed as part of an LDRD effort (FY11 to FY13; project number 151364) to meet these needs.

AN EXTENDED FINITE ELEMENT METHOD FORMULATION FOR MODELING THE RESPONSE OF POLYCRYSTALLINE MATERIALS TO DYNAMIC LOADING

The eXtended Finite Element Method (X‐FEM) is a finite‐element based discretization technique developed originally to model dynamic crack propagation [1]. Since that time the method has been used for modeling physics ranging from static meso‐scale material failure to dendrite growth. Here we adapt the recent advances of Vitali and Benson [2] and Song et al. [3] to model dynamic loading of a polycrystalline material. We use demonstration problems to examine the methods efficacy for modeling the dynamic response of polycrystalline materials at the meso‐scale. Specifically, we use the X‐FEM to model grain boundaries. This approach allows us to i) eliminate ad‐hoc mixture rules for multi‐material elements and ii) avoid explicitly meshing grain boundaries.