Additive Layer Manufactured (ALM) Aerospace Part

Posted on May 14, 2011 by io

EADS Innovation Works optimized Airbus A320 nacelle hinge bracket (link). The manufacturing method of choice was Additive Layer Manufacturing (ALM), so no manufacturing constraints was necessary. The component was originally made of steel , but now the material of choice was Ti6Al4V. A %64 reduction in weight was obtained, with a preserved level of stiffness and decreased (halved) maximum stress, and a bit lowered maximum bolt force. The optimization was done in two stages, the first on was scraped, where the errors seems to be origination from improper boundary conditions. The final structure seems not to be utilising the full potential of free ALM structures.

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Mercedes SLS AMG

Posted on May 13, 2011 by io

The aluminium space-frame chassis of SLS AMG is made of: %45 aluminium extrusions , %31 aluminium sheet, %20 cast aluminium and %4 steel. Steel is used only at A pillars for maximum safety. The castings were topology optimized (link). The whole aluminium space-frame weights 241 kilograms. Due to the unusual (Targa?) style of the roof, even the roof has a thick, topology optimized component, probably to bear the forces concentrated in the area, and provide safety in the case of a crash.

Cast aluminium parts

One of the optimized structures, probably the roof one

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Formula SAE Wheel Center

Posted on May 12, 2011 by io

Vandals Racing team of University of Idaho used topology optimization to develope the wheel centers of their car (link). The centers are reported to be at the same weight an size as previous wheels centers and the stress is reduced by half.

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Poll

Posted on May 12, 2011 by io

Our first poll
[polldaddy poll=4702834]

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CH-47 Chinook under floor frame

Posted on May 10, 2011 by io

Under floor frames of CH-47 Chinook were investigated, and topology optimized by Boeing and NCDMM (link). Possibility of using monolithic “one-piece machining” structures, which is an increasing trend in aviation and topology optimization of such structures were  studied. Ramp downs in the ribs were utilized as can be seen from the photo below, which permits further weight reductions.

It is stated that %15 weight reduction was obtained as an average of all 4 cases studied. 3 profiles, namely T, I and + were studied, where I profile did not have connected edges, which does not seem to be ideal.

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Compliant Aircraft Wing Leading Edge

Posted on May 10, 2011 by io

M.J. Santer and S. Pellegrinoy topology optimized a Compliant Aircraft Wing Leading Edge. Using Genetic Algorithms and a path based method. The aim seems to be designing an elastic Leading edge with no gap. The results seem a bit trivial with respect to other compliant mechanisms designed by  topology optimization (we have covered none so far).

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Solar Car

Posted on May 10, 2011 by io

Group T Leuven Engineering College a team of fourteen engineering students used topology optimization to design the structure of a solar car (link). The frame is 19 kg in weight, and has covered 3000 km’s of road. They utilised inertia relief method, which is suitable for unconstrained structures, which covers most moving structures (e.g. bikes, airplanes, boats, cars).

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Composite Rudder Quadrant

Posted on April 18, 2011 by io

Engineering company High Modulus and composite rudder specialist Isotop, developed a CFRP rudder quadrant for a 100-ft/31m boat to reduce its weight (link). Topology optimization was utilized to design the part. The original structure had a core with sheet CFRP surfaces. The optimized structure is rather a truss structure with %25 weight loss.

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Heller machining centres

Posted on April 10, 2011 by io

Heller (link) uses topology optimization to improve their machine components. They optimized their topologies with respect to both static and eigenvalue responses. All the targeted eigenfrequencies were increased significantly.

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ForcePAD

Posted on April 10, 2011 by io

ForcePAD is a very nice, little educational topology optimizing software. It is similar to Paint in terms of interface. You just paint a 2D structure with a brush kind of tool, place forces with few clicks and do the topology optimization very quickly. There is no elaborate modeling needed or meshing etc. Even an elementary school student can play with it and learn about topology optimization. Of course it is free too.I did optimize something shape like Pikachu, and all from painting to end of optimization took less than two minutes.

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