Topology Optimization and Design for Additive Manufacturing: the case study of a hydraulic module for automotive application

The aim of this work is to follow the entire value chain of a mechanical metallic hydraulic module that is produced with the additive manufacturing process called Laser Powder Bed Fusion (L-PBF). Different software is used: Siemens NX 12 and Altair Inspire 2019 for CAD, Siemens NX Nastran 12 and Altair Inspire 2019 for FEA and topology optimization, and Materialise Magics 21.11 for support structure creation. A comparison between the software used for CAD, FEA analyses and topology optimizations is presented. The customer provides all the technical information related to the component to perform a structural FEA. After the definition and extension of the design space, loads and constraints are applied on the non-design space and a topology optimization with Solid Isotropic Material with Penalization (SIMP) method is performed. Afterwards it is necessary to rebuild the component with freeform and bionic shapes, making sure that all the parts are connected. After the reconstruction, a further FEA is performed to prove that the optimized part can withstand the loads. The results of this analysis are compared with the results of the analysis of the initial geometry. To make the machining easier, fixtures and stock material are added. The final component will be tested on a bench to prove its efficiency. In conclusion, all the advantages and disadvantages of both software are compared to better understand which could be the better in the additive manufacturing industry. NX/NX Nastran are the best option for CAD modification and FEA but Inspire can perform topology optimization and reconstruction faster. In addition, additive manufacturing production technology is evaluated for this specific component: it results convenient only for a small production lot.