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Conception pour la fabrication additive : approche méthodologique pour les systèmes mécaniques multicorps

Abstract : Topological optimization (TO) is a mathematical tool used to obtain an optimal distribution of material density. From a given volume, subjected to loads, the TO leads to a concept of part fulfilling an objective and respecting constraints. The optimized part shapes are often too complex to be manufacturable thanks conventional processes. Additive manufacturing (AM) allows the material to be deposited where it is needed. Consequently, the choice of AM to manufacture topological optimized parts is often wise. In scientific literature, published design methods often remain applied to a single mechanical part, with few articles dealing with the design optimization of a product. The purpose of this PhD is to suggest a design method of an additively manufactured multibody mechanical system. It is composed of parts linked together and have relative motions. For this purpose, and in order to take advantage of all the possibilities of the AM, this manuscript suggests in a first step a classification of the optimizations achievable during the design of a product. Three optimizations are identified: architectural optimization, functional optimization and topological optimization. Both the application timeline and a demonstration of the contributions of each optimization are established. In a second step, a topology optimization methodology of multibody systems (denoted TOMS for Topological Optimization of a Mechanical System) is developed to take into account the interaction of the mass and inertia decrease on each part of the system. An organization chart is introduced. It presents a method of loop optimization in order to take into account new boundary conditions. Then, different paths for managing the impact of inertia are shown. Finally, a path ranking taking into account the objectives of the designer is proposed and some optimization principles are suggested. At last, these three optimizations are one step in the process of designing a product. In order to achieve this step with all the skills and knowledge in AM, a global design methodology is proposed. This methodology helps designers to design a single part as well as a multi-body mechanical system, from the specifications to final product.
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Myriam Orquéra. Conception pour la fabrication additive : approche méthodologique pour les systèmes mécaniques multicorps. Mécanique des matériaux [physics.class-ph]. Université de Toulon, 2019. Français. ⟨NNT : 2019TOUL0018⟩. ⟨tel-02895646⟩

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