Integrating topology optimization and additive manufacturing (AM) technology can facilitate innovative product development. However, laser powder bed fusion, which is the predominant method in metal AM, can lead to issues such as residual stress and deformation. Recently, topology optimization methods considering these stresses and deformations have been proposed; however, they suffer from challenges caused by an increased computational cost. In this study, we propose a method for reducing computational cost in topology optimization considering the deformation in AM. An inherent strain method-based analytical model is presented for simulating the residual stress and deformation in the AM process. Subsequently, a constraint condition to suppress the deformation is formulated, and a method to reduce the computational cost of the adjoint analysis in deriving sensitivity is proposed. The minimum mean compliance problem considering AM deformation and self-support constraints can then be incorporated into the level set-based topology optimization framework. Finally, numerical examples are presented for validating the effectiveness of the proposed topology optimization method.

翻译：将拓扑优化与增材制造（AM）技术相结合有助于促进创新产品开发。然而，作为金属增材制造主流方法的激光粉末床熔融技术可能导致残余应力和变形等问题。近期虽已提出考虑这些应力与变形的拓扑优化方法，但此类方法因计算成本增加而面临挑战。本研究提出一种在增材制造变形约束下降低拓扑优化计算开销的方法：首先建立基于固有应变法的分析模型以模拟增材制造过程中的残余应力与变形；其次构建抑制变形的约束条件，并提出在灵敏度推导过程中降低伴随分析计算量的方法；随后可将同时考虑增材制造变形与自支撑约束的最小平均柔度问题融入基于水平集的拓扑优化框架。最后通过数值算例验证所提拓扑优化方法的有效性。