面向增材制造的航空发动机外部系统支架拓扑优化设计

doi:10.3969/j.issn.1004-132X.2022.23.006

摘要/Abstract

摘要： 分析了严酷载荷工况下航空发动机外部系统支架的力学性能，以两种极限载荷工况下的支架柔顺度为目标函数，采用增材制造材料横观各向同性模型，开展了面向增材制造的外部系统支架拓扑优化设计与性能校核。金属激光增材制造样件的力学试验表明：面向增材制造的支架设计较初始结构质量减小约15%，刚度增大约20%，一阶固有频率提高约15%，结构强度显著增大。该方案实现了1个外部系统支架、2个管路支架和4颗铆钉的一体化增材制造，有效提升了发动机装配质量和效率，顺利通过地面静载和发动机点火试验。

关键词: 拓扑优化, 变密度法, 外部系统支架, 多载荷工况, 增材制造

Abstract: The mechanics properties of aero-engine external system supports under critical loading conditions were analyzed. The support smoothness under two kinds of ultimate load conditions was used as objective function. The topology optimization design and performance check of external system supports for additive manufacturing were conducted using transverse isotropic model of additive manufacturing materials. The results of the mechanics test of metal laser additive manufacturing samples shows that， compared with the initial structure， the support design for additive manufacturing has a 15% less material usage， the stiffness increases by about 20%， and the first-order natural frequency improves by 15%. The structural strength increases significantly. The integrated additive manufacturing with 1 external system support， 2 piping supports and 4 rivets was realized herein， which effectively improves the quality and efficiency of engine assembly. The ground static load and engine ignition tests were successfully passed.

Key words: , topology optimization, variable density method, external system bracket, multiple loading condition, additive manufacturing

中图分类号:

V232.7

孟亮, 仲明哲, 李文彪, 夏凉, 高彤, 朱继宏, 张卫红, . 面向增材制造的航空发动机外部系统支架拓扑优化设计[J]. 中国机械工程, 2022, 33(23): 2822-2832.

MENG Liang, ZHONG Mingzhe, LI Wenbiao, XIA Liang, GAO Tong, ZHU Jihong, ZHANG Weihong, . Topology Optimization Design of Aero-engine External System Brackets for Additive Manufacturing[J]. China Mechanical Engineering, 2022, 33(23): 2822-2832.

导出引用管理器 EndNote|Ris|BibTeX

链接本文: https://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2022.23.006

https://www.cmemo.org.cn/CN/Y2022/V33/I23/2822

参考文献

［1］唐术. 基于加工、装配与维护的航空发动机外部系统设计研究［D］. 成都：电子科技大学， 2009.
TANG Shu. Research on Design of Aero-engine External System Based on Machining， Assembly and Maintenance［D］. Chengdu：University of Electronic Science and Technology of China， 2009.
［2］朱继宏，李军朔，张卫红，等. 现代形状优化技术在航空发动机零部件设计中的应用［J］. 航空制造技术， 2012， 55（23/24）：30-35.
ZHU Jihong， LI Junshuo， ZHANG Weihong， et al. Applications of Advanced Shape Optimization Technology in Structural Design of Aeroengine［J］. Aeronautical Manufacturing Technology， 2012， 55（23/24）：30-35.
［3］CHEN L， ZHANG W， MENG L， et al. An Adaptive T-spline Finite Cell Method for Structural Shape Optimization［J］. Structural and Multidisciplinary Optimization， 2020， 61（5）：1857-1876.
［4］FENG S， ZHANG W， MENG L， et al. Stiffener Layout Optimization of Shell Structures with B-spline Parameterization Method［J］. Structural and Multidisciplinary Optimization， 2021， 63（6）：2637-2651.
［5］TANG L， GAO T， SONG L， et al. Topology Optimization of Nonlinear Heat Conduction Problems Involving Large Temperature Gradient［J］. Computer Methods in Applied Mechanics and Engineering， 2019， 357：112600.
［6］LI Y， GAO T， ZHOU Q Y， et al. Layout Design of Thin-walled Structures with Lattices and Stiffeners Using Multi-material Topology Optimization［J/OL］. Chinese Journal of Aeronautics， 2022［2022-08-26］. https：∥doi. org/10. 1016/j. cja. 2022. 07. 022.
［7］ZHANG Z J， ZHANG R T， ZHU J H， et al. Integrated Batteries Layout and Structural Topology Optimization for a Solar-powered Drone［J］. Chinese Journal of Aeronautics， 2021， 34（7）：114-123.
［8］XIE Y M， STEVEN G P. A Simple Evolutionary Procedure for Structural Optimization［J］. Computers & Structures， 1993， 49（5）：885-896.
［9］LI X， GAO L， ZHOU Y， et al. A Hybrid Level Set Method for the Integrated Optimization of Structural Topology and Multicomponent Layout［J］. International Journal for Numerical Methods in Engineering， 2021， 122（11）：2802-2828.
［10］MENG L， ZHANG W H， ZHU J H， et al. Shape Optimization of Axisymmetric Solids with the Finite Cell Method Using a Fixed Grid［J］. Acta Mechanica Sinica， 2016， 32（3）：510-524.
［11］CAI S Y， ZHANG W H， GAO T， et al. Adaptive Bubble Method Using Fixed Mesh and Topological Derivative for Structural Topology Optimization［J］. Chinese Journal of Theoretical and Applied Mechanics， 2019， 51（4）：1235-1244.
［12］GAO J， XIAO M， ZHANG Y， et al. A Comprehensive Review of Isogeometric Topology Optimization：Methods， Applications and Prospects［J］. Chinese Journal of Mechanical Engineering， 2020， 33（6）：24-37.
［13］ZHANG W， JIU L， MENG L. Buckling-constrained Topology Optimization Using Feature-driven Optimization Method［J］. Structural and Multidisciplinary Optimization， 2022， 65：37.
［14］SHI G H， GUAN C Q， QUAN D L， et al. An Aerospace Bracket Designed by Thermo-elastic Topology Optimization and Manufactured by Additive Manufacturing［J］. Chinese Journal of Aeronautics， 2020， 33（4）：1252-1259.
［15］ZHU J H， ZHANG W H， XIA L. Topology Optimization in Aircraft and Aerospace Structures Design［J］. Archives of Computational Methods in Engineering， 2016， 23（4）：595-622.
［16］JANKOVICS D， BARARI A. Customization of Automotive Structural Components Using Additive Manufacturing and Topology Optimization［J］. IFAC-PapersOnLine， 2019， 52（10）：212-217.
［17］JEWETT J L， CARSTENSEN J V. Topology-optimized Design， Construction and Experimental Evaluation of Concrete Beams［J］. Automation in Construction， 2019， 102：59-67.
［18］ZHENG Y H， WANG Y C， CHEN R K， et al. Tissue Transformation Mold Design and Stereolithography Fabrication［J］. Rapid Prototyping Journal， 2017， 23（1）：162-168.
［19］BUTLER J. Using Selective Laser Sintering for Manufacturing［J］. Assembly Automation， 2011， 31（3）：212-219.
［20］KRUTH J P， FRO YEN L， VAN VAERENBERGH J， et al. Selective Laser Melting of Iron-based Powder［J］. Journal of Materials Processing Technology， 2004， 149（1/3）：616-622.
［21］TAYLOR A C， BEIRNE S， ALICI G， et al. System and Process Development for Coaxial Extrusion in Fused Deposition Modelling［J］. Rapid Prototyping Journal， 2017， 23（3）：543-550.
［22］PAOLINI A， KOLLMANNSBERGER S， RANK E. Additive Manufacturing in Construction：a Review on Processes Applications， and Digital Planning Methods［J］. Additive Manufacturing， 2019， 30：100894.
［23］SEABRA M， AZEVEDO J， ARAUJO A， et al. Selective Laser Melting（SLM）and Topology Optimization for Lighter Aerospace Components［J］. Procedia Structural Integrity， 2016， 1：289-296.
［24］CULMONE C， SMIT G， BREEDVELD P. Additive Manufacturing of Medical Instruments：a State-of-the-art Review［J］. Additive Manufacturing， 2019， 27：461-473.
［25］DILBEROGLU U M， GHAREHPAPAGH B， YAMAN U， et al. The Role of Additive Manufacturing in the Era of Industry 4.0［J］. Procedia Manufacturing， 2017， 11：545-554.
［26］GEBISA A W， LEMU H G. Design for Manufacturing to Design for Additive Manufacturing：Analysis of Implications for Design Optimality and Product Sustainability［J］. Procedia Manufacturing， 2017， 13：724-731.
［27］XIA L， BREITKOPF P. Concurrent Topology Optimization Design of Material and Structure within FE2 Nonlinear Multiscale Analysis Framework［J］. Computer Methods in Applied Mechanics and Engineering， 2014， 278：524-542.
［28］XIA L， BREITKOPF P. Multiscale Structural Topology Optimization with an Approximate Constitutive Model for Local Material Microstructure［J］. Computer Methods in Applied Mechanics and Engineering， 2015， 286：147-167.
［29］XIA L， BREITKOPF P. Recent Advances on Topology Optimization of Multiscale Nonlinear Structures［J］. Archives of Computational Methods in Engineering， 2017， 24（2）：227-249.
［30］ZHOU L， ZHANG W H. Topology Optimization Method with Elimination of Enclosed Voids［J］. Structural and Multidisciplinary Optimization， 2019， 60（1）：117-136.
［31］MORGAN H D， CHERRY J A， JONNALA-GADDA S， et al. Part Orientation Optimization for the Additive Layer Manufacture of Metal Components［J］. The International Journal of Advanced Manufacturing Technology， 2016， 86（5）：1679-1687.
［32］JIU L， ZHANG W， MENG L， et al. A CAD-oriented Structural Topology Optimization Method［J］. Computers & Structures， 2020， 239：106324.
［33］SONG L， GAO T， TANG L， et al. An All-movable Rudder Designed by Thermo-elastic Topology Optimization and Manufactured by Additive Manufacturing［J］. Computers & Structures， 2021， 243：106405.
［34］MENG L， ZHANG W， QUAN D， et al. From Topology Optimization Design to Additive Manufacturing：Todays Success and Tomorrows Roadmap［J］. Archives of Computational Methods in Engineering， 2020， 27（3）：805-830.
［35］TOMLIN M， MEYER J. Topology Optimization of an Additive Layer Manufactured（ALM）Aerospace Part［C］∥ The 7th Altair CAE Technology Conference2011. Gaydon， Warwickshire， 2011：1-9.
［36］WU Y， QIU W， XIA L， et al. Design of an Aircraft Engine Bracket Using Stress-constrained Bi-directional Evolutionary Structural Optimization Method［J］. Structural and Multidisciplinary Optimization， 2021， 64（6）：4147-4159.
［37］SHI G H， GUAN C Q， QUAN D L， et al. An Aerospace Bracket Designed by Thermo-elastic Topology Optimization and Manufactured by Additive Manufacturing［J］. Chinese Journal of Aeronautics， 2020， 33（4）：1252-1259.
［38］BENDSE M P. Optimal Shape Design as a Material Distribution Problem［J］. Structural Optimization， 1989， 1：193-202.
［39］BENDSE M P， SIGMUND O. Material Interpolation Schemes in Topology Optimization［J］. Archive of Applied Mechanics， 1999， 69：635-654.
［40］ROZVANY G. Aims， Scope， Methods， History and Unified Terminology of Computer-aided Topology Optimization in Structural Mechanics［J］. Structural and Multidisciplinary Optimization， 2001， 21（2）：90-108.
［41］STOLPE M， SVANBERG K. On the Trajectories of Penalization Methods for Topology Optimization［J］. Structural and Multidisciplinary Optimization， 2001， 21（2）：128-139.

[1]	王浩, 罗浩东, 施亚中, 王立文, 张威, 王忠. 基于端到端深度学习模型TOPO-U型网的结构拓扑优化方法[J]. 中国机械工程, 2026, 37(1): 174-183.
[2]	熊晓晨, 周岩, 周祥曼, 吴海华, 华林, 胡泽启, 秦训鹏, 邓少华. 随动热锤辅助水轮机关键过流部件电弧增材再制造强塑协同调控[J]. 中国机械工程, 2025, 36(12): 3010-3016.
[3]	吕谦, 刘维伟. 增材喷管收扩段磨粒流光整分子动力学仿真与参数优化研究[J]. 中国机械工程, 2025, 36(12): 3017-3022.
[4]	何昆, 周和超, 张济民. 列车防爬吸能器负泊松比超材料填充结构设计[J]. 中国机械工程, 2025, 36(12): 3040-3046.
[5]	杨凯, 王磊, 汤永凯, 刘谋斌, 郭子傲. 面向高端装备的金属激光增材制造技术发展与应用[J]. 中国机械工程, 2025, 36(09): 2068-2080.
[6]	黄昊1, 王曾2, 李波2, 卢泽华1, 刘怀举1. 基于折衷规划法的航发齿轮传动壳体结构热柔度协同拓扑优化[J]. 中国机械工程, 2025, 36(07): 1471-1478.
[7]	姜峰1, 2, 胡荣辉1, 邓杰东1, 张添1, 黄国钦1, 2, 徐仰立1, 2, 李友生3, 刘超4. 硬质合金刀具增材制造技术发展趋势和展望[J]. 中国机械工程, 2025, 36(06): 1300-1313.
[8]	苏珂1, 王颖1, 梁腾腾1, 魏义礼2, 张楠楠2. 基于知情构造理论的单材料柔性机构拓扑优化[J]. 中国机械工程, 2025, 36(04): 873-881.
[9]	林家辉, 李壮壮, 李学霖, 李军. 一种路径吞噬拓扑优化新方法[J]. 中国机械工程, 2025, 36(03): 504-514.
[10]	王书亭1, 谢晴天1, 杨奥迪1, 李小兵2, 熊体凡1, 谢贤达2. 等几何拓扑优化非齐次边界条件施加技术研究[J]. 中国机械工程, 2025, 36(03): 525-535.
[11]	姜世杰1, 2, 许子沼1, 李曙光1, 王菲1, 黄绪震3. 17-4PH不锈钢材料的金属熔丝成形及其制品力学性能研究[J]. 中国机械工程, 2025, 36(03): 593-603.
[12]	刘敏1, 2, 卢飞扬1, 占金青1, 2, 吴剑1, 朱本亮3. 考虑最小尺寸约束的内嵌可移动压电驱动柔顺机构拓扑优化设计[J]. 中国机械工程, 2025, 36(02): 255-264.
[13]	吴蒙华1, 姜炳春1, 肖雨晴2, 贾卫平2. 磁场对无掩模定域性电沉积增材制造三维微结构生长模式的影响[J]. 中国机械工程, 2024, 35(11): 2035-2042.
[14]	张珞1, 刘明明2, 陈锐敏1, 但鹏1, 郭楠1. 激光选区熔化成形大尺寸薄壁件变形控制仿真与试验研究[J]. 中国机械工程, 2024, 35(09): 1653-1658，1709.
[15]	王浩1, 2, 王江北3, 罗浩东3, 王立文4. 基于改进四叉树和比例边界有限元法的自适应设计域拓扑优化方法[J]. 中国机械工程, 2024, 35(05): 904-915,927.