Topology Optimization Design of Aero-engine External System Brackets for Additive Manufacturing

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

Abstract

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

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

CLC Number:

V232.7

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.

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.

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