<p>Topology optimization, a structural optimization method that allows us to obtain lighter and more performance structures with its wide design area while offering more complex geometries. With additive manufacturing technologies, complex structures that are difficult to produce with traditional methods are produced. The integrated use of additive manufacturing technologies with topology optimization is a very effective approach to produce lighter and more performance structures. In the present study, the application of topology optimization in Ansys 2019 R1 software for a bearing bracket used in the aircraft warehouse door system and its production with additive manufacturing technologies are discussed. Considering the safety factor value, topology optimization for three different materials (i.e. Ti6Al4V, 316L stainless steel and Maraging steel) on the bearing bracket, arrangements and analysis were carried out on the geometry obtained due to the optimization. As a result of the analysis, the strength properties obtained based on the optimized geometry for Maraging steel, Ti6Al4V alloy and stainless steel materials were determined as follows: the safety factor values were 1.6421, 1.3201 and 0.7606 respectively; the total deformation (mm) was 1.0643, 1.4065 and 0.8207 respectively; and the weight (kg) was reduced to 0.3637, 0.2014 and 0.3592, achieving a 58.55% reduction. After topology optimization, the original bracket volume for Maraging steel was reduced from 109.67 to 33.97 cm<sup>3</sup>. It has been observed that the geometries obtained through topology optimization of all three selected materials are suitable for production through additive manufacturing. ST-PLA, 1.75 mm was used as the printing material. Its suitability for prototype production and additive manufacturing was tested and confirmed, and it was produced using laser powder bed fusion with the Maraging steel.</p>

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Topology optimization for manufacturing aircraft bearing brackets via laser powder bed fusion

  • MUSTAFA TOK,
  • YUSUF FEDAI

摘要

Topology optimization, a structural optimization method that allows us to obtain lighter and more performance structures with its wide design area while offering more complex geometries. With additive manufacturing technologies, complex structures that are difficult to produce with traditional methods are produced. The integrated use of additive manufacturing technologies with topology optimization is a very effective approach to produce lighter and more performance structures. In the present study, the application of topology optimization in Ansys 2019 R1 software for a bearing bracket used in the aircraft warehouse door system and its production with additive manufacturing technologies are discussed. Considering the safety factor value, topology optimization for three different materials (i.e. Ti6Al4V, 316L stainless steel and Maraging steel) on the bearing bracket, arrangements and analysis were carried out on the geometry obtained due to the optimization. As a result of the analysis, the strength properties obtained based on the optimized geometry for Maraging steel, Ti6Al4V alloy and stainless steel materials were determined as follows: the safety factor values were 1.6421, 1.3201 and 0.7606 respectively; the total deformation (mm) was 1.0643, 1.4065 and 0.8207 respectively; and the weight (kg) was reduced to 0.3637, 0.2014 and 0.3592, achieving a 58.55% reduction. After topology optimization, the original bracket volume for Maraging steel was reduced from 109.67 to 33.97 cm3. It has been observed that the geometries obtained through topology optimization of all three selected materials are suitable for production through additive manufacturing. ST-PLA, 1.75 mm was used as the printing material. Its suitability for prototype production and additive manufacturing was tested and confirmed, and it was produced using laser powder bed fusion with the Maraging steel.