An Aggregation-Free Local Volume Fraction Formulation for Topological Design of Porous Structure

Cellular structure can possess superior mechanical properties and low density simultaneously. Additive manufacturing has experienced substantial progress in the past decades, which promotes the popularity of such bone-like structure. This paper proposes a methodology on the topological design of porous structure. For the typical technologies such as the p-norm aggregation and implicit porosity control, the violation of the maximum local volume constraint is inevitable. To this end, the primary optimization problem with bounds of local volume constraints is transformed into unconstrained programming by setting up a sequence of minimization sub-problems in terms of the augmented Lagrangian method. The approximation and algorithm using the concept of moving asymptotes is employed as the optimizer. Several numerical tests are provided to illustrate the effectiveness of the proposed approach in comparison with existing approaches. The effects of the global and local volume percentage, influence radius and mesh discretization on the final designs are investigated. In comparison to existing methods, the proposed method is capable of accurately limiting the upper bound of global and local volume fractions, which opens up new possibilities for additive manufacturing.