Gradient anisotropic design of Voronoi porous structures

•A novel gradient anisotropic design method of Voronoi porous structures is proposed.•The stress scalar field controls the gradient of the GAVP parts globally.•The stress direction field tailors the anisotropy of the Voronoi cells locally.•The GAVP part is highly profile adaptable based on a Voronoi cell growth strategy. Gradient and anisotropic design have proved to be two effective approaches for customizing lightweight porous parts in recent years due to their outstanding performances comparing to the uniform porous ones, such as high specific strength, specific surface areas and high energy and shock absorption capacities, etc. However, it is still challenging to integrate both gradient and anisotropy into a same porous part, while making it profile adaptable simultaneously. In this paper, a novel gradient anisotropic design method of Voronoi porous structures for parts customization is proposed driven by the stress field of a part in a specific application scenario. Firstly, the stress field is decomposed into a stress scalar field and a stress direction field. The former is mapped into the Voronoi site distribution by a weighted random sampling algorithm that globally controls the gradient of the mechanical properties, while the latter is applied to adjust the shapes and orientations of the Voronoi cells for tailoring the anisotropy locally. Then, a lightweight gradient anisotropic Voronoi porous (GAVP) part is customized based on a Voronoi cell growth strategy with preferred directions, making the porous part highly profile adaptable. Finally, the influences of the design parameters on the mechanical properties of the GAVP parts are analyzed in detail, and the proposed design method is further validated experimentally and numerically. The results show that the integration of gradient and anisotropy significantly enhances the mechanical properties of a GAVP part compared to the corresponding gradient porous or anisotropic porous ones, because our GAVP structure modeling method realize a more optimal allocation of material locally, which makes the stress distribution much more even. [Display omitted]