A Novel Mathematical Formulation for Density-Based Topology Optimization Method Considering Multi-Axis Machining Constraint

Abstract This paper proposes a novel density-based method for structural design considering restrictions of multi-axis machining processes. A new mathematical formulation based on Heaviside function is presented to transform the field into geometry which can be manufactured by process. The developed 5-axis machining, also applied 2.5D milling restriction. filter techniques are incorporated effectively control minimum size void region. proposed demonstrated solving compliance minimization problem different machinable freeform designs. length diameter (L:D) ratio geometric constraint introduced ensure design, where deep hole or narrow chamber features avoided using method. Several two- and three-dimensional numerical examples discussed in detail.