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A simple method to automatically update the finite element mesh of the analysis domain is proposed. The method considers the mesh as a fictitious elastic body subjected to prescribed displacements at selected boundary points. The mechanical properties of each mesh element are appropriately selected in order to minimize the deformation and the distortion of the mesh elements. Different selection strategies have been used and compared in their application to simple examples. The method avoids the use of remeshing in the solution of shape optimization problems and reduces the number of remeshing steps in the solution of coupled fluid–structure interaction problems.

A simple method to automatically update the finite element mesh of the analysis domain is proposed for cases when the shape of the domain in modified. The method considers the mesh as a fictitious elastic body subjected to prescribed displacement at selected boundary points. The mechanical properties of each mesh element are appropriately selected in order to minimize the deformation and the distortion of the mesh elements. Different selection strategies have been used of remeshing in the solution of shape optimization problems and reduces the number of the remeshing step in the solution of coupled fluid-structure interaction problems

It is well-known that many manufacturing parameters affect the quasi-static and the fatigue response of additive manufacturing (AM) parts. In particular, due to the layer-by-layer production, the load orientation, with respect to the building direction, plays a fundamental role for the fatigue response. This paper investigates the fatigue response up to 109 cycles (very high cycle fatigue (VHCF)) of selective laser melting (SLM) AlSi10Mg specimens built in a vertical direction. Ultrasonic tension-compression tests (stress ratio of -1) are carried out on as-built Gaussian specimens with a large loaded volume (2300 mm3). Fracture surfaces are investigated with the scanning electron microscope to analyze the defects originating the VHCF failure. Probabilistic S-N curves are estimated and analyzed. Experimental results confirm that the defect size controls the VHCF response, thus highlighting the importance of testing large risk volumes for a reliable assessment of VHCF behavior. The average value of the VHCF strength is close to that of the hourglass specimen tested in the literature. The variability of the VHCF strength is instead significantly larger, due to the scattered size distribution of the defects located near the specimen surface, which is the most critical region for crack initiation.

The present paper proposes a new technique for the definition of the shape design variables in 2D and 3D optimisation problems. It can be applied to the discrete model of the analysed structure or to the original geometry without any previous knowledge of the analytical expression of the CAD defining surfaces. The proposed technique allows the surface continuity to be preserved during the geometry modification process to be defined a priori. This capability allows for the definition of shape variables suitable for every kind of discipline involved in the optimisation process (structural analysis, fluid-dynamic analysis, crash analysis, aerodynamic analysis, etc.).