Shuzhi Xu (徐庶之)

Shuzhi Xu (徐庶之)

Topology Optimization for LPBF

This research focuses on developing advanced optimization methodologies for manufacturing processes, integrating computational mechanics, thermal-mechanical coupling, and process planning. Our work is structured into several **sub-directions** that collectively aim to enhance manufacturability, reduce residual stresses, and achieve high-precision fabrication.
## 1. Research Background
We investigate heat transfer, mechanical response, and residual stress evolution during additive manufacturing processes. These studies form the theoretical foundation for developing optimization algorithms and predictive simulation tools.
## 2. LPBF Simulation Solver ### 2.1. Thermal-Elastic-Plastic Solver

Detailed documentation is being prepared.

### 2.2. Thermal Solver (Overheating Prediction)

Detailed documentation is being prepared.

### 2.3. Simplified Solver Based on the Inherent Strain Method #### 2.3.1. Solver Framework ![Simulation flow chart based on inherent strain method](/images/manufacturing_process/研究1-1.png)

Simulation flow chart based on inherent strain method.

#### 2.3.2. Simulation Process

Simulation process: (left) Fusion process; (right) Cut-off process.

#### 2.3.3. Results Validation ![Comparison with commercial software](/images/manufacturing_process/研究1-3.png)

Comparison with commercial software shows errors below 5%, demonstrating solver reliability.

[🔗 Related MATLAB Code](https://www.mech.sdu.edu.cn/info/1132/129552.htm) ## 3. Design Optimization Based on the Inherent Strain Method

3.1. Residual Stress Constrained Structure Topology Optimization

Residual-stress-constrained topology optimization results.

3.2. Scanning Path Optimization for Residual Distortion Reduction

Since it is quite easy to set or adjust such island scanning path of the laser for the metal AM machine, a systemic metal AM-oriented island-type scanning pattern optimization method is therefore proposed in this work.

3.2.1. Problem Definition

The illustration of scanning island.

3.2.2. Modeling

The anisotropic property of inherent strain and modeling.

3.2.3. Optimization Framework

Optimization framework for island scanning-pattern design.

Evolution of the optimized island scanning pattern.

Residual-distortion response during the optimization process.

3.2.4. Related Publication

[1] Xu, S., Huang, J., Liu, J., Ma, Y., & Liu, J. (2022). An Island Scanning Path-Pattern Optimization for Metal Additive Manufacturing Based on Inherent Strain Method. Computer-Aided Design and Applications, 19(4), 812-824. [Paper]

[2] Xu, S., Huang, J., Liu, J., & Ma, Y. (2021). Island Scanning Path-Pattern Optimization for Residual Distortion Control in Metal Additive Manufacturing. Proceedings of CAD’21, Barcelona, Spain, July 5–7, 2021, pp. 66–72. [Paper]

3.3. Concurrent Structure and Path Optimization for Residual Distortion Reduction

3.3.1. Optimization Framework

Concurrent optimization framework for structure and scanning pattern.

3.3.2. Optimization Results

Optimized structure, scanning pattern, and residual-distortion results.

3.3.3. Related Publication

Xu, S., Liu, J., Li, X., & Ma, Y. (2023). Concurrent Island scanning pattern and large-scale topology optimization method for laser powder bed fusion processed parts. Finite Elements in Analysis and Design, 225, 104018. [Paper]

3.4. Support Structure Design for LPBF

3.4.1. Optimization results

Support-structure optimization results considering residual distortion.

3.4.2. Related Publication

Xu, S., Liu, J., Sun, Y., Li, X., & Ma, Y. (2024). Support structure topology optimization considering the residual distortion for laser powder bed fusion metal additive manufacturing. Structural and Multidisciplinary Optimization, 67(10), 1–20. [Paper]