Design optimization for manufacturability of axisymmetric continuum structures using metamorphic development

In this study, optimal shapes/profiles of axisymmetric continuum structures optimized for performance and manufacturability are sought, using a topology/shape optimization method called metamorphic development (MD). The optimization seeks to find an optimum cross-sectional profile and minimum weight design, subjected to von-Mises stress constraints under coupled thermal and pressure loadings. Both quadrilateral and triangular finite elements (FE) were used to ‘metamorphically’ develop the structure. Two different design optimization approaches were taken, by defining a set of finite ‘restricted’ and ‘unrestricted’ design domains. Manufacturability of the optimized structures was considered. Prior to manufacturing, a post-optimization process was performed. A comparison was then performed for both sets of optimized solutions to demonstrate whether the ‘restricted’ design domain solution gave greater or lesser performance characteristics compared to the ‘unrestricted’ design domain solution which could only be manufactured by additive manufacturing technologies (AMT). The results of the optimization demonstrated the success of the MD method in generating practical design solutions which meet both performance requirements and manufacturing considerations.