End-to-end process of hollow spacecraft structures with high frequency and low mass obtained with in-house structural optimization tool and additive manufacturing

INCAS Bulletin

Radu-Petru BIBIRE¹  Alexandru-Mihai CISMILIANU²  Camelia Elena MUNTEANU³  Ionut-Cosmin ONCESCU⁴  Mihai Victor PRICOP⁵  Valentin STOENESCU⁶  Elisabeth REY⁷  Sébastien EYRIGNOUX⁸ 

[1] INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail];INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail]*;INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail];INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail];INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail];INCAS – National Institute for Aerospace Research “Elie Carafoli”, B-dul Iuliu Maniu 220, Bucharest 061126, Romania, [e-mail];LAAM - LISI AEROSPACE ADDITIVE MANUFACTURING Powered by POLY-SHAPE, 2, route Robert Algayon, Ayguemorte-les-Graves 33640, France, [e-mail];LAAM - LISI AEROSPACE ADDITIVE MANUFACTURING Powered by POLY-SHAPE, 2, route Robert Algayon, Ayguemorte-les-Graves 33640, France;

关键词: end-to-end;    in-house tool;    structural optimization;    topology optimization;    3D Printing;    additive manufacturing;    ALM;    hollow;    powder removal;    metal powders;    high frequency;    low mass;    space applications;    mass reduction;    cost saving;    minimum lead time;   

DOI  :  10.13111/2066-8201.2017.9.3.2

来源: DOAJ

【 摘 要 】

In the space sector the most decisive elements are: mass reduction, cost saving and minimum lead time; here, structural optimization and additive layer manufacturing (ALM) fit best. The design must be driven by stiffness, because an important requirement for spacecraft (S/C) structures is to reduce the dynamic coupling between the S/C and the launch vehicle. The objective is to create an end-to-end process, from the input given by the customer to the manufacturing of an aluminum part as light as possible but at the same time considerably stiffer while taking the full advantage of the design flexibility given by ALM. To design and optimize the parts, a specialized in-house tool was used, guaranteeing a load-sufficient material distribution. Using topological optimization, the iterations between the design and the stress departments were diminished, thus greatly reducing the lead time. In order to improve and lighten the obtained structure a design with internal cavities and hollow beams was considered. This implied developing of a procedure for powder evacuation through iterations with the manufacturer while optimizing the design for ALM. The resulted part can be then manufactured via ALM with no need of further design adjustments. To achieve a high-quality part with maximum efficiency, it is essential to have a loop between the design team and the manufacturer. Topological optimization and ALM work hand in hand if used properly. The team achieved a more efficient structure using topology optimization and ALM, than using conventional design and manufacturing methods.

【 授权许可】

Unknown