This paper presents a comprehensive numerical and experimental study on stress-constrained topology optimization for Fused Deposition Modeling (FDM) additive manufacturing. The qp method is employed to avoid the singularity issue of stress-constrained problems. The P-norm function with stability transformation is adopted to build the global stress constraint with iterative corrections to eliminate the gap between the maximum local stress and the P-norm stress. The Heaviside projection is employed to generate clear-cut 0–1 designs. Two benchmark examples have been studied with the numerical algorithm. Experiments are performed on the topologically optimized MBB beam to investigate the impact of the FDM process parameters, including deposition path direction, building direction, and slicing layer height, on the resulted structural strength. The stress-constrained designs without and with Heaviside projection are comparatively tested with experiments. The stress-minimization designs subject to different P-norm parameters are compared both numerically and experimentally. Experiments show that the deposition path direction and the building direction evidently affect the derived structural strength. Moreover, overthin structural members may severely degrade the structural strength due to manufacturing and loading uncertainties.

中文翻译：

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材料挤出聚合物增材制造的应力约束拓扑优化

本文对熔融沉积建模 (FDM) 增材制造的应力约束拓扑优化进行了全面的数值和实验研究。该QP方法来避免应力约束问题的奇异性问题。采用具有稳定性变换的P范数函数构建全局应力约束，迭代修正消除最大局部应力与P范数应力之间的差距。Heaviside 投影用于生成清晰的 0-1 设计。已经用数值算法研究了两个基准示例。对拓扑优化的 MBB 梁进行实验，以研究 FDM 工艺参数（包括沉积路径方向、构建方向和切片层高度）对所得结构强度的影响。没有和有 Heaviside 投影的应力约束设计通过实验进行了比较测试。在数值和实验上比较了受不同 P 范数参数影响的应力最小化设计。实验表明，沉积路径方向和建筑方向明显影响导出的结构强度。此外，由于制造和负载的不确定性，过薄的结构构件可能会严重降低结构强度。