Customization of Automotive Structural Components using Additive Manufacturing and Topology Optimization

Multimaterial multijoint topology optimization

https://par.nsf.gov/servlets/purl/10208125

Sensitivity analysis and lattice density optimization for sequential inherent strain method used in additive manufacturing process

A multiobjective topology optimization approach for cost and time minimization in additive manufacturing

To date, topology optimization has proven to be the most beneficial, yet most complex, structural optimization technique available to engineers and scientists. However, particularly in the aerospace industry, there exists little application to real-world design problems, including all the complexities required to ensure that the resulting design complies with the regulations. In this paper, a topology optimization algorithm is developed to solve aerospace design problems. Two problems are considered in this work. The first is the design of an aircraft landing gear. The final topology is compared to a design found using standard engineering practices to show the benefits of topology optimization. The second problem uses the topology optimization methodology to design an aircraft engine mount. The main goal of this paper is to demonstrate that topology optimization can be used to find minimum weight structures to aerospace design problems, using Federal Aviation Regulations to ensure that the resulting designs meet the airworthiness standards of the aviation industry.

On the benefits of applying topology optimization to structural design of aircraft components

Aircraft landing gear assemblies comprise of various subsystems working in unison to enable functionalities such as taxiing, take-off and landing. As development cycles and prototyping iterations begin to shorten, it is important to develop and improve practical methodologies to meet certain design metrics. This paper presents an efficient methodology that applies high-fidelity multi-disciplinary design optimization techniques to commercial landing gear assemblies, for weight, cost, and structural performance by considering both structural and dynamic behaviours. First, a simplified landing gear assembly model was created to complement with an accurate slave link subassembly, generated based of drawings supplied from the industrial partner, Safran Landing Systems. Second, a Multi-Body Dynamic (MBD) analysis was performed using realistic input motion signals to replicate the dynamic behaviour of the physical system. The third stage involved performing topology optimization with results from the MBD analysis; this can be achieved through the utilization of the Equivalent Static Load Method (ESLM). Lastly, topology results were generated and design interpretation was performed to generate two designs of different approaches. The first design involved trying to closely match the topology results and resulted in a design with an overall weight savings of 67%, peak stress increase of 74%, and no apparent cost savings due to complex features. The second design focused on manufacturability and achieved overall weight saving of 36%, peak stress increase of 6%, and an estimated 60% in cost savings.

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Design optimization of aircraft landing gear assembly under dynamic loading

As the field of design for additive manufacturing continues to evolve and accelerate towards admitting more robust designs requiring fewer instances of user-intervention, we will see the conventional design cycle evolve dramatically. However, to fully take advantage of this emerging technology — particularly with respect to large scale manufacturing operations — considerations of productivity from a fiscal perspective are sure to become of the utmost importance. A mathematical model incorporating the cost and time factors associated with additive manufacturing processes has been developed and implemented as a multi-weighted single-objective topology optimization algorithm. The aforementioned factors have been identified as component surface area and volume of support material. These quantities are optimized alongside compliance, producing a design tool that gives the user the option to choose the relative weighting of performance over cost. In two academic examples, minimization of compliance alongside surface area and support structure volume yield geometries demonstrating that considerable decreases in support material in particular can be achieved without sacrificing significant part compliance.

Minimization of Cost and Print Time of Additive Manufacturing via Topology Optimization

Advanced Finite Element Analysis of a Lightweight Nanometal-Polymer Hybrid Component with Experimental Validation, and Its Applications to Vehicle Lightweighting

Luke Ryan

Papers

Design optimization of aircraft landing gear assembly under dynamic loading

A multiobjective topology optimization approach for cost and time minimization in additive manufacturing

Minimization of Cost and Print Time of Additive Manufacturing via Topology Optimization

Advanced Finite Element Analysis of a Lightweight Nanometal-Polymer Hybrid Component with Experimental Validation, and Its Applications to Vehicle Lightweighting