Topology optimization design of new honeycomb sandwich structures for additive manufacturing
Additive manufacturing,as an emerging technology,offers an efficient and high-precision approach for fabricating honeycomb structures. However,traditional honeycomb core design methods based on design experi-ence and mechanical experiments often fall short in fully exploiting material potential and innovating structural configurations,leading to suboptimal load-bearing capacity of honeycomb structures. This paper introduced a new topology optimization design method for honeycomb core structures tailored for additive manufacturing. Uti-lizing numerical homogenization theory,the macroscopic equivalent elastic properties of honeycomb core micro-structures were predicted. Subsequently,the optimization objective was set to maximize the shear modulus or bulk modulus of the honeycomb core microstructure,with material usage as a constraint,establishing a topology optimization model for honeycomb core microstructures tailored for additive manufacturing. During the sensitivi-ty analysis in the topology optimization model,consistency constraints on sensitivity information were imposed to achieve honeycomb core structures with cross-sectional consistency,facilitating high-quality forming in addi-tive manufacturing. Case study results demonstrate that the proposed method increases the shear modulus of the designed novel honeycomb core structure by 58.62％ and 60.08％ compared to traditional hexagonal and honey-comb-like honeycomb structures,with bulk modulus increases of 11.91％ and 31.82％,respectively. The method,by fully exploring the design space of honeycomb cores,significantly enhances their mechanical performance,meeting the requirements of additive manufacturing processes. The research findings provide theoretical referenc-es for the design and configuration innovation of high-load honeycomb core structures.
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