Tunable deformation design of porous Al2O3 based on the Direct FE2 method

Abstract The tunable deformation design of porous ceramics has raised many interests in many engineering and manufacturing fields, where its corresponding design methodologies still suffer from the lower efficiency and higher computational cost. To handle this problem, a novel optimization and design methodology based on the Direct FE2 method has been proposed in this study, and several numerical examples of the porous Al2O3 tunable deformation design has been performed by this novel methodology. Compared with the traditional methodologies, the proposed method is more convenient to conduct the tunable deformation design and improves the optimization efficiency. Based on this method, the distribution and assembly of the microscale representative volume element could be tailored along the space dimension to handle the sinusoidal deformation and variable Poisson’s ratio ceramic design at the macroscale. By comparing the simulation results with the direct numerical simulation model, the effectiveness and accuracy of this methodology is well validated. Meanwhile, the simulation results based on the proposed methodology found that the predictability of porous Al2O3 deformation could be enhanced by changing the micro structure parameters such as the elliptical hole angle and aspect ratio. This methodology holds great potential for applications in the design and optimization of porous ceramics with tailored deformation characteristics.