The study involves an examination of the rotor fixture assembly to understand its functionality under standard boundary conditions. The fixture components were modelled in NX CAD. To achieve the desired weight reduction and equivalent stiffness, Finite Element Analysis was conducted both before and after the Topology Optimization process using the Density-based method in ANSYS. The objective was to optimize rotor fixture design for additive manufacturing to reduce weight and lead time. Finite Element Analysis and topology optimization were used to redesign the fixture, resulting in a 16.3% mass reduction for the solid model and 27.5% for the shell model while maintaining stiffness. Metal additive manufacturing reduced lead time by 46% despite a 17% increase in cost compared to conventional machining. Future work may involve lattice structure design and part distortion prediction using Ansys additive software for further improvements.
In the ever-evolving landscape of additive manufacturing (AM), where intricate and precise component assembly is crucial, the role of rotor fixtures has become increasingly vital. These fixtures, designed to secure and stabilize rotor components during assembly, play a pivotal role in ensuring the integrity and functionality of a wide range of machinery and systems. The assembly of rotors, central to various industries such as aerospace, automotive, and energy production, demands meticulous attention to detail to achieve optimal performance, safety, and longevity. This assessment embarks on a comprehensive exploration of rotor fixtures used in the context of additive manufacturing, aiming to delve into their design intricacies, functionality, and the impact they have on the overall quality of rotor assemblies.
Additive manufacturing, often referred to as 3D printing, has revolutionized the way we produce complex parts and components. Its versatility and ability to create intricate geometries have led to widespread adoption in various industries. However, with this advancement comes a unique set of challenges, particularly in the realm of rotor assembly. Unlike traditional manufacturing methods, additive manufacturing introduces factors such as layer-by-layer deposition, material properties, and thermal considerations, all of which can significantly influence the assembly process and the final quality of the rotor.
A. Design Consideration
Development of Conceptual Model of Rotor Fixture:
This step involves creating an initial design or concept for a rotor fixture. It's important to consider factors like the rotor's size, shape, and the specific requirements of the fixture to hold it securely.
Topology Optimization for Rotor Fixture to Reduce Mass with Same Stiffness - Topology optimization is a computational approach used in engineering to optimize the material distribution within a given design space. In this case, you're aiming to reduce the mass of the rotor fixture while maintaining its stiffness. This involves running simulations and calculations to identify areas where material can be removed without compromising structural integrity.
Redesigning the Rotor Fixture with Reference to the Topologically Optimized Design - Once the topology optimization is complete, you'll use the results as a reference to redesign the rotor fixture. Involves translating the optimized material distribution into a practical.
Comparing the Original Design and Manufacturing Process with the New Design and Manufacturing Process of the Rotor Fixture - After redesigning the rotor fixture, it's crucial to perform a detailed comparison between the original design and manufacturing process and the new design and manufacturing process. This comparison should take into account factors such as mass, stiffness, cost, and ease of manufacturing. It's likely that the new design will offer advantages in terms of reduced mass, but it's essential to ensure that other critical factors are also considered.
In conclusion, the rotor fixture is redesigned to reduce the weight and keeping the same or more stiffness of material by applying the Topology optimization method using mass response constraint. Optimizing the components by redesigning to satisfies the research objectives. Static structural analysis is carried out to know the behaviour of stress and deformation in the rotor fixture. For existing design, the maximum stress value of rotor fixture is 6.9153 MPa and the maximum deformation is 0.00251 mm. For new solid body design, the maximum stress value of rotor fixture is 9.8341 MPa and the maximum deformation is 0.00275 mm. For new shell body design, the maximum stress value of rotor fixture is 27.487 MPa and the maximum deformation is 0.00709 mm. Conventional machining cost for rotor fixture is € 9450 which will have a Leadtime of 63 days. But the Metal Additive Manufacturing cost for printing rotor fixture is 17 % higher which is € 11440, and which will have a 46% reduction in Lead time of 34 days.
The project involved assessment of additive manufacturing by reducing the weight of the rotor fixture by applying topology optimization. Further, the work can be broadened by Applying lattice structure design to the rotor fixture parts could reduce the mass even more than by using only Topology Optimization. A new Mechanism could be incorporated along with the movement of the central and side pads can be automated. Part distortion and part shape prediction simulation can be done using Ansys additive software.
 Bendsoe, M.P.; Sigmund, O. Topology Optimization: Theory, Methods and Applications; Springer: Berlin, Germany, 2003; pp. 1–68.
 Sotola, M.; Marsalek, P.; Rybansky, D.; Fusek, M.; Gabriel, D. Sensitivity Analysis of Key Formulations of Topology Optimization on an Example of Cantilever Bending Beam. Symmetry 2021, 13, 712.
 Zhu, J.H.; Zhang, W.H.; Xia, L. Topology Optimization in Aircraft and Aerospace Structures Design. Arch. Comput. Methods Eng. 2016, 23, 595–622.
 Hanush, S.S.; Manjaiah, M. Topology optimization of aerospace part to enhance the performance by Finite manufacturing process. Mater. Today Proc. 2022, 62, 7373–7378.
 Prathyusha, A.L.R.; Babu, G.R. A review on additive manufacturing and topology optimization process for weight reduction studies in various industrial applications. Mater. Today Proc. 2022, 62, 109–117.
 Jankovics, D.; Barari, A. Customization of Automotive Structural Components using Additive Manufacturing and Topology Optimization. IFAC-Pap. 2019, 52, 212–217.
 Bao, D.W.; Yan, X.; Snooks, R.; Xie, Y. Bioinspired Generative Architectural Design Form-Finding and Advanced Robotic Fabrication Based on Structural Performance 2020. In Architectural Intelligence, Selected Papers from the 1st International Conference on Computational Design and Robotic Fabrication; Yuan, P., Xie, M., Leach, N., Yao, J., Wang, X., Eds.; Springer: Singapore, 2019; pp. 147–170.
 Li, Y.; Lai, Y.; Lu, G.; Yan, F.;Wei, P.; Xie, Y.M. Innovative design of long-span steel–concrete composite bridge using multi-material topology optimization. Eng. Struct. 2022, 269, 114838.
 Reis, P.; Volpini, M.; Maia, J.P.; Guimarães, I.B.; Evelise, C.; Monteiro, M.; Rubio, J.C.C. Resting hand splint model from topology optimization to be produced by additive manufacturing. Rapid Prototyp. J. 2022, 28, 216–225.
 Muzalewska, M. Methodology of Multicriterial Optimization of Geometric Features of an Orthopedic Implant. Appl. Sci. 2021, 11, 11070.