In the whole project (M1-M48), four technical work packages (WP) were involved with the following research and technological activities.
In WP1, we designed a computational framework for microstructural representation of curved (aka freeform) geometries based on volumetric representations (V-Rep) that are compatible with the state-of-the-art boundary representation (B-rep). In particular, we investigated a specific truss lattice construction arising from spherical packing, we analyzed microtiling of trimmed trivariates, explored geometrical strategies to generate irregular auxetic structures and/or looked at efficient computation of Hausdorff distance between two free-form objects.
In WP2, we dealt with structural analysis of a microstructured pattern using an iso-geometric framework using the input of WP1. In particular, we developed a fast solver that exploits the similarities among lattices to perform simulations of large microstructures geometries with a very low computational burden. We studied shape optimization of the internal microstructure by considering various (basis) microtiles and used thickness distribution for their optimization.
In WP3, we considered problems of highly accurate surface finish using 5-axis CNC machining. In particular, we considered higher order contact between a conical milling tool and a free-form surface, and for special target geometries, such as spiral bevel gears and/or screw rotors, we considered milling with two sides of the milling tool (aka double-flank milling) using a specifically designed custom-shaped tool. We also considered a hybrid manufacturing of aeronautic components, such as blade integrated disks, whose internal microstructure was 3D printed and the final surface finish was completed by 5-axis CNC machining.
In WP4, we applied the full workflow designed in WP1, WP2, and WP3 to several test cases. We implemented numerical tools in Hutchinson’s in-house code Numea and successfully applied the methods to a representative product in a way that cannot be achieved with conventional tools. The turbine blade test case demonstrated not only the design and simulation possibility but also the manufacturing and control possibility of the thin metallic microstructure showing the industrial possibility offered by ADAM^2 outcomes.
Overall, we submitted 48 conference and/or journal papers, from which, up to date, 46 are published, and the remaining two are under review. The published papers appeared in top journals such as Transactions of Computer Graphics, Computer Graphics Forum, Computer-Aided Design, Computer Methods in Applied Mechanics and Engineering, Computational Mechanics, or Precision Engineering. We delivered more than 35 technical presentations (24 conference presentations and 11 research visits) at top events such as SIGGRAPH, EUROGRAPHICS, ECCOMAS, or SPM, and presented our results on several industrial fairs such as BIENH, ECO, or CONTROL. We also published an article in a science-popularizing journal Research OUTREACH.
