ADVANCED LATTICE AND POROUS STRUCTURES FOR AM PRODUCT OPTIMIZATION

The present work aims at favoring development of strategies useful for innovative high-performance mechanical components design. One of the most promising but not yet adequately explored strategies to achieve this goal are lattice / porous structures to be used as structural or filler materials to increase performance in terms of stiffness to weight ratio and enhanced vibration damping. To fill this knowledge gap, static and dynamic behavior of SLM-manufactured lattice structures made in AlSi10Mg aluminum alloy and 316L austenitic stainless steel have been thoroughly investigated; in particular, the study allowed to observe the effect of lattice’s unit cell geometry and overall size variation on its mechanical properties, focusing on damping performances. Acquired knowledge allowed to develop a versatile methodology that can be applied to assess the mechanical properties of different kinds of lattice / porous structures, facilitating FE models calibration, creation of homogenization methods and mathematical models useful for lattices static and dynamic behavior rapid estimation. The development of an innovative tool for in-process measurement of cutting forces that develop in milling, drilling and grinding, integrating specially designed lattice structures, represents a practical case study useful to assess the feasibility of exploiting lattice structures to enhance mechanical components performances. Transversal expertise gained with respect to the SLM process, design and optimization of mechanical components and lattice structures, allowed to develop and validate an innovative methodology for rapid production of small-sized lattice structures (Patent Pending). An appropriate experimental campaign allowed to identify optimized process parameters, suitable for the production of lattices using the proposed methodology. The proposed method enhances the overall manufacturing process efficiency; moreover, since it allows substantial savings in terms of time and costs it has both scientific and industrial relevance.