Havacılık uygulamalarında eklemeli imalat için uyarlanabilir topoloji optimizasyonu

Abstract

Topoloji optimizasyonu, havacılık endüstrisinde önemli bir yöntem ve mühendislerin, ağırlıklarını azaltırken yüksek performanslı uçak bileşenleri geliştirmelerini sağlamıştır. Ayrıca, daha önce geleneksel imalat yöntemleri kullanılarak üretilmesi mümkün olamayacak karmaşık yapıların tasarımına da olanak sağlamıştır. Bu çalışmada, nTopology yazılımı kullanılarak bir uçağın iniş takımları için direksiyon pompası muhafazasının kapsamlı topoloji optimizasyonu gerçekleştirilmiştir. Bu optimizasyonun birincil amacı, iniş takımı sisteminin emniyetli ve güvenilir çalışması için gerekli olan mekanik özelliklerini korurken direksiyon pompası mahfazasının ağırlığını azaltmaktır. Çalışma, topoloji optimizasyonunun, mekanik özelliklerini korurken uçak bileşenlerinin ağırlığını azaltmak için etkili bir araç olduğunu göstermektedir. Bu yaklaşım, benzer tasarım zorluklarına sahip uçak bileşenlerine uygulanarak, potansiyel olarak uçağın genel tasarımında önemli ağırlık tasarrufları sağlayabilecektir.

Keywords

• Topoloji
• Optimizasyon
• Voronoi
• Gyroid
• Eklemeli imalat

Adaptive topology optimization for additive manufacturing in aerospace applications

Abstract

Topology optimization has become a valuable tool in the aerospace industry, enabling engineers to develop aircraft components with improved performance characteristics while reducing their weight. The technique has also allowed for the design of complex structures that were previously unattainable using traditional manufacturing methods. In this study, a comprehensive topology optimization of the steering pump housing for an aircraft's nose landing gear was performed using the nTopology software. The primary objective of this optimization was to reduce the weight of the steering pump housing while preserving its mechanical properties, which are essential for safe and reliable operation of the nose landing gear system. The study demonstrates the potential for topology optimization to be an effective tool for reducing the weight of aircraft components while preserving their mechanical properties. This approach can be applied to other aircraft components with similar design challenges, and could potentially lead to significant weight savings in the overall design of the aircraft.

Keywords

• Topology
• Optimization
• Voronoi
• Gyroid
• Additive manufacturing

References

1. [1] Noronha W, Joshi V, Jeyanthi S. "Design of 3D printed aircraft seat structure using latticing in combination with topology optimization and generative design". International Conference on Applications in Computational Engineering and Sciences, Chennai, India, 30-31 October 2020.
2. [2] Munk DJ, Waddell E, Vaziri R, Gärtner T. "On the benefits of applying topology optimization to structural design of aircraft components". Structural and Multidisciplinary Optimization, 60(4), 1245-1266, 2019.
3. [3] Prathyusha ALR, Raghu Babu G. "A review on additive manufacturing and topology optimization process for weight reduction studies in various industrial applications". Materials Today: Proceedings, 62, 109-117, 2022.
4. [4] Wu J, Sigmund O, Groen JP. "Topology optimization of multi-scale structures: a review". Structural and Multidisciplinary Optimization, 63(3), 1455-1480, 2021.
5. [5] Meng L, Zhang W, Quan D, Shi G, Tang L, Hou Y, Gao T. "From topology optimization design to additive manufacturing: Today’s success and tomorrow’s roadmap". Archives of Computational Methods in Engineering, 27(3), 805-830, 2020.
6. [6] Tyflopoulos E, Steinert M. "A Comparative study of the application of different commercial software for topology optimization". Applied Sciences, 12(2), 1-23, 2022.
7. [7] Jafferson JM, Sharma H. "Design of 3D printable airless tyres using NTopology". Materials Today: Proceedings, 46, 1147-1160, 2021.
8. [8] Dagkolu A, Gokdag I, Yilmaz O. "Design and additive manufacturing of a fatigue-critical aerospace part using topology optimization and L-PBF process". Procedia Manufacturing, 54, 238-243, 2021.

9. [9] Baumeister S, Leung A, Ryley T. "The emission reduction potentials of first generation electric aircraft (FGEA) in Finland". Journal of Transport Geography, 85, 1-8, 2020.
10. [10] Gray N, McDonagh S, O'Shea R, Smyth B, Murphy JD. "Decarbonising ships, planes and trucks: An analysis of suitable low-carbon fuels for the maritime, aviation and haulage sectors". Advances in Applied Energy, 1, 1-24, 2021.
11. [11] Oh MK, Lee DS, Yoo J. "Stress constrained topology optimization simultaneously considering the uncertainty of load positions". International Journal for Numerical Methods in Engineering, 123(2), 339-365, 2022.
12. [12] Essassi K, Rebiere JL, ElMahi A, Souf MAB, Bouguecha A, Haddar M. "Experimental and analytical investigation of the bending behaviour of 3D-printed bio-based sandwich structures composites with auxetic core under cyclic fatigue tests". Composites Part A: Applied Science and Manufacturing, 131, 1-21, 2020.
13. [13] Miralbes R, Santamaria N, Ranz D, Gómez JA. "Study of the anisotropy of triple periodic minimal surface structures generate by additive manufacturing". International Joint Conference on Mechanics, Design Engineering & Advanced Manufacturing, Ischia, Italy, 1-3 june 2022.
14. [14] Sulaymon TA, Petri HT, Rayko T. "Towards a complex geometry manufacturing: A case study on metal 3D printing of topology optimised bicycle parts with lattices". IFAC-PapersOnLine, 55(10), 1515-1520, 2022.
15. [15] Nirish M, Rajendra R. "Suitability of metal additive manufacturing processes for part topology optimization-A comparative study". Materials Today: Proceedings, 27, 1601-1607, 2020.
16. [16] Moj K, Robak G, Owsiński R, Kurek A, Żak K, Przysiężniuk D. "A new approach for designing cellular structures: design process, manufacturing and structure analysis using a volumetric scanner". Journal of Mechanical Science and Technology, 37, 1113-1118, 2023.
17. [17] Harithsa SN, Kumar SA, Nagesha BK, Nataraj JR. "Computational study on subsonic impact resistance of lattice structures in 3D printed thin Ti6Al4V parts". Materials Today: Proceedings, 87(1), 74-79, 2023.
18. [18] Jihong ZHU, Han ZHOU, Chuang WANG, Lu ZHOU, Shangqin YUAN, Zhang, W. "A review of topology optimization for additive manufacturing: Status and challenges". Chinese Journal of Aeronautics, 34(1), 91-110, 2021.
19. [19] Sathishkumar N, Vivekanandan N, Balamurugan L, Arunkumar N, Ahamed I. "Mechanical properties of triply periodic minimal surface-based lattices made by PolyJet printing". Materials Today: Proceedings, 22, 2934-2940, 2020.
20. [20] Nakanishi K, Labonte D, Cebo T, Veigang-Radulescu VP, Fan Y, Brennan B, Fleck NA. "Mechanical properties of the hollow-wall graphene gyroid lattice". Acta Materialia, 201, 254-265, 2020.
21. [21] Szatkiewicz T, Laskowska D, Bałasz B, Mitura K. "The ınfluence of the structure parameters on the mechanical properties of cylindrically mapped gyroid TPMS fabricated by selective laser melting with 316L stainless steel powder". Materials, 15(12), 1-22, 2022.
22. [22] Yang L, Wu S, Yan C, Chen P, Zhang L, Han C, Shi Y. "Fatigue properties of Ti-6Al-4V Gyroid graded lattice structures fabricated by laser powder bed fusion with lateral loading". Additive Manufacturing, 46, 1-18, 2021.
23. [23] Fu YFJ. "Recent advances and future trends in exploring Pareto-optimal topologies and additive manufacturing-oriented topology optimization". Mathematical Biosciences and Engineering, 17(5), 4631-4656, 2020.
24. [24] Goodwin LA, Schmidt DW, Kuettner L, Patterson BM, Walker E, Edgar A, Schmitt MJ. "Development of stochastic voronoi lattice structures via two-photon polymerization". Fusion Science and Technology, 78(1), 66-75, 2022.
25. [25] Lei HY, Li JR, Xu ZJ, Wang QH. "Parametric design of Voronoi-based lattice porous structures". Materials & Design, 191, 1-10, 2020.
26. [26] Babamiri BB, Barnes B, Soltani-Tehrani A, Shamsaei N, Hazeli K. "Designing additively manufactured lattice structures based on deformation mechanisms". Additive Manufacturing, 46, 1-19, 2021.
27. [27] Liu P, Liu A, Peng H, Tian L, Liu J, Lu L. "Mechanical property profiles of microstructures via asymptotic homogenization". Computers & Graphics, 100, 106-115, 2021.
28. [28] Baxter G. "Assessing the carbon footprint and carbon mitigation measures of a major full-service network airline: A case study of Singapore Airlines". International Journal of Environment, Agriculture and Biotechnology, 7(5), 81-107, 2022.
29. [29] Gu D, Shi X, Poprawe R, Bourell DL, Setchi R, Zhu J. "Material-structure-performance integrated laser-metal additive manufacturing". Science, 372(6545), 1-15 2021.
30. [30] Sithole C, Nyembwe K, Olubambi P. "Process knowledge for improving quality in sand casting foundries: A literature review". Procedia Manufacturing, 35, 356-360, 2019.
31. [31] Sapkal SU, Patil IC, Darekar SK. Dimensional Variation and Wear Analysis of 3D Printed Pattern for Sand Casting. Editors: Yadav S, Singh DB, Arora PK, Kumar H. Smart Innovation, Systems and Technologies, 461-470, India, Springer, 2019.
32. [32] Pham T, Kwon P, Foster S. "Additive manufacturing and topology optimization of magnetic materials for electrical machines-a review". Energies, 14(2), 1-24, 2021.
33. [33] Wang L, Liu Y, Wang X, Qiu Z. "Convexity-oriented reliability-based topology optimization (CRBTO) in the time domain using the equivalent static loads method". Aerospace Science and Technology, 123, 1-20, 2022.
34. [34] Goh GD, Toh W, Yap YL, Ng TY, Yeong WY. "Additively manufactured continuous carbon fiber-reinforced thermoplastic for topology optimized unmanned aerial vehicle structures". Composites Part B: Engineering, 16, 1-10, 2021.
35. [35] Kartini K, Sipayung GA, Ismail R, Jamari J, Bayuseno AP. "Data transfer analysis of the homogeneous rough surface of a solid model into a CAE system with varying file data formats". Cogent Engineering, 9(1), 1-14, 2022.
36. [36] Karaçam F, Arda ÖC. "Topology optimization of the load-carrying element under a concentrated load". Trakya Üniversitesi Mühendislik Bilimleri Dergisi, 22(2), 57-64. 2021.
37. [37] Merulla A, Gatto A, Bassoli E, Munteanu SI, Gheorghiu B, Pop MA, Bedo T, Munteanu D. "Weight reduction by topology optimization of an engine subframe mount, designed for additive manufacturing production". Materials Today: Proceedings, 19(3), 1014-1018, 2019.