Abstract：
This paper presents a novel approach for designing a freeform bending-resistant structure from the combination of explicit discrete component-based topology optimization (TO) and the porcupine quill-inspired features. To embed the porcupine quill\'s features into the TO formulations, the method involves constructing discrete components at various scales to imitate features including solid shell, stochastically distributed pores, and graded stiffeners. The components are iteratively updated, and the optimization process allows for the grading of quill-inspired features while achieving optimal structural compliance under bending loads. The proposed approach is demonstrated to be effective through the resolution of Messershmitt-Bolkow-Blohm (MBB) beam designs, parameterized studies of geometric parameters, and numerical validation of long-span and short-span quill-inspired beam designs. By examining the von Mises stress distribution, the study highlights the mitigation of material yielding at the shell region brought by the geometric features of porcupine quills, leading to the potential theory support for the bending resistance. The optimized MBB beams are manufactured using the material extrusion technique, and three-point bending tests are conducted to explore the failure mitigation capability of the quill-inspired beam under large deformation. Consequently, the study concludes that the proposed quill-inspired component-based TO approach can design a structure with excellent bending resistance according to the improved energy absorption as well as increased deformation after reaching 75% peak load.
摘要：
本文提出了一种新颖的方法，用于设计基于显式离散组件的拓扑优化和豪猪羽毛启发的功能相结合的防故障抗弯结构。为了在经典拓扑优化公式下实现故障安全功能，该方法包括构建各种尺度的离散组件，以模仿羽毛笔的泡沫状特征。组件迭代更新，并且优化过程允许在弯曲载荷下实现最佳结构顺应性的同时对羽毛笔启发特征进行分级。通过Messershmitt-Bolkow-Blohm（MBB）光束设计的分辨率证明了所提出的方法是有效的，几何参数的参数化研究，并对大跨度和短跨度羽毛梁设计进行了数值验证。通过检查冯·米塞斯的应力分布，这项研究强调了豪猪羽毛的几何特征所带来的材料产量的缓解，导致对故障安全能力的潜在理论支持。优化的MBB梁使用材料挤压（MEX）技术制造，并进行了三点弯曲试验，探讨了在大变形条件下偏心梁的失效缓解能力。因此,研究得出的结论是，提出的基于羽毛笔启发的组件的拓扑优化方法可以根据改进的能量吸收以及达到75％峰值载荷后的变形增加来设计故障安全结构。
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