Hansu Kim, Luke Crispo, Anuj Patel, Nicholas Galley, S. Yeon, Yong Son, Il Yong Kim
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引用次数: 0
摘要
目的飞机座椅的轻量化设计可显著提高燃油效率并减少温室气体排放。金属增材制造(MAM)可以生产出拓扑优化的轻质设计并提高性能,但有限的制造体积限制了大型部件的打印。本文的目的是利用拓扑优化(TO)和 MAM,在满足结构适航认证要求的前提下,设计一种轻质飞机座椅腿结构。对概念设计进行了分解,以满足机器的制造体积,设计了详细的 CAD 装配,并为每个组件选择了打印方向。进行了静态和动态验证,更新了设计以满足结构要求,并制造了一个原型。此外,该设计在满足适航认证结构要求的同时,还减少了 8.5% 的质量。原创性/价值 据作者所知,本研究是第一篇采用严格的 TO 方法设计飞机座椅腿结构的论文。与参考设计相比,该设计减少了质量和零件数量,并根据实际飞机认证要求进行了验证。
Design of a metal additive manufactured aircraft seat leg using topology optimization and part decomposition
Purpose
The lightweight design of aircraft seats can significantly improve fuel efficiency and reduce greenhouse gas emissions. Metal additive manufacturing (MAM) can produce lightweight topology-optimized designs with improved performance, but limited build volume restricts the printing of large components. The purpose of this paper is to design a lightweight aircraft seat leg structure using topology optimization (TO) and MAM with build volume restrictions, while satisfying structural airworthiness certification requirements.
Design/methodology/approach
TO was used to determine a lightweight conceptual design for the seat leg structure. The conceptual design was decomposed to meet the machine build volume, a detailed CAD assembly was designed and print orientation was selected for each component. Static and dynamic verification was performed, the design was updated to meet the structural requirements and a prototype was manufactured.
Findings
The final topology-optimized seat leg structure was decomposed into three parts, yielding a 57% reduction in the number of parts compared to a reference design. In addition, the design achieved an 8.5% mass reduction while satisfying structural requirements for airworthiness certification.
Originality/value
To the best of the authors’ knowledge, this study is the first paper to design an aircraft seat leg structure manufactured with MAM using a rigorous TO approach. The resultant design reduces mass and part count compared to a reference design and is verified with respect to real-world aircraft certification requirements.
期刊介绍:
Rapid Prototyping Journal concentrates on development in a manufacturing environment but covers applications in other areas, such as medicine and construction. All papers published in this field are scattered over a wide range of international publications, none of which actually specializes in this particular discipline, this journal is a vital resource for anyone involved in additive manufacturing. It draws together important refereed papers on all aspects of AM from distinguished sources all over the world, to give a truly international perspective on this dynamic and exciting area.
-Benchmarking – certification and qualification in AM-
Mass customisation in AM-
Design for AM-
Materials aspects-
Reviews of processes/applications-
CAD and other software aspects-
Enhancement of existing processes-
Integration with design process-
Management implications-
New AM processes-
Novel applications of AM parts-
AM for tooling-
Medical applications-
Reverse engineering in relation to AM-
Additive & Subtractive hybrid manufacturing-
Industrialisation