AĞIRLIK AZALTMA AMACIYLA ELEKTRON IŞINI İLE ERGİTME YÖNTEMİYLE ÜRETİLEN BİR UÇAK PARÇASININ TASARIMI, TOPOLOJİ OPTİMİZASYONU VE TESTİ

Öz

Bu çalışmanın amacı, konvansiyonel üretim kısıtlarına uygun olarak tasarlanan bir uçak parçasının, topoloji optimizasyonu yöntemleri kullanılarak, aynı yükleme koşullarına dayanacak şekilde, ağırlığının azaltılabileceğini göstermektir. Bu amaçla, optimizasyon sonucu elde edilen parça geometrisi, sonlu elamanlar analizine tabi tutulmuş ve aynı yükleme koşullarında plastik deformasyon göstermediği gösterilmiştir. Optimize edilmiş geometri, elektron ışınıyla ergitme (EIE) yöntemiyle, Ti6Al4V malzemeden üretilmiş ve parçada meydana gelen boyutsal sapmalar ölçülmüştür. Ölçüm sonuçlarından elde edilen sapmaların, montaj toleransları dahilinde olduğu görülmüştür. Son olarak, üretilen parça statik teste tabi tutulmuş ve numerik sonuçlar ile test sonuçlarının uyumlu olduğu gösterilmiştir. Bütün bu çalışmalar neticesinde, bir uçak parçasının topoloji optimizasyonu ile, aynı yükleme koşullarına dayanacak şekilde, ağırlığının %40.7 oranında azaltılabileceği, EIE yöntemiyle başarılı bir şekilde üretilebileceği ve test verilerine dayanarak, uçakta kullanılabileceği gösterilmiştir.

Anahtar Kelimeler

• Topoloji Optimizasyonu
• Elektron Işını ile Ergitme
• Titanyum
• Eklemeli İmalat
• Boyutsal Sapma

DESIGN, TOPOLOGY OPTIMIZATION AND TESTING OF AN AIRCRAFT PART PRODUCED BY ELECTRIN BEAM MELTING FOR WEIGHT REDUCTION

Öz

The aim of this study is to show that weight of an aircraft part designed based on conventional manufacturing restrictions can be reduced by using topology optimization methods along with withstanding the same loading conditions. For this purpose, the geometry of the part obtained by optimization was subjected to finite elements analysis and no plastic deformation under the same loading conditions was observed. Optimized geometry was produced by electron beam melting (EBM) method with Ti6Al4V material and dimensional deviations in the produced part were measured. The deviations from the measurement results were found to be within the installation tolerances. Finally, the produced part was subjected to static testing and it was shown that numerical results and test results were found to be compatible. As a result of all these studies, it was shown that the weight of an aircraft part withstanding the same loading conditions can be reduced by 40.7 % by using topology optimization method, produced successfully by EBM method and used in aircraft based on test data.

Anahtar Kelimeler

• Topology Optimization
• Electron Beam Melting
• Titanium
• Additive Manufacturing
• Dimensional Variation

Kaynakça

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