Topology Synthesis of Extrusion-Based Nonlinear Transient Designs

Many practical structural designs require that the structure is easily manufactured. Design concepts synthesized using conventional topology optimization methods are typically not easily manufactured, in that multiple finishing processes are required to construct the component. A manufacturing technique that requires only minimal effort is extrusion. Extrusion is a manufacturing process used to create objects of a fixed cross-sectional profile. The result of using this process is lower costs for the manufacture of the final product. In this paper, a hybrid cellular automaton algorithm is developed to synthesize constant cross section structures that are subjected to nonlinear transient loading. The novelty of the proposed method is the ability to generate constant cross section topologies for plastic-dynamic problems since the issue of complex gradients can be avoided. This methodology is applied to extrusions with a curved sweep along the direction of extrusion as well. Three-dimensional examples are presented to demonstrate the efficiency of the proposed methodology in synthesizing these structures. Both static and dynamic loading cases are studied.