Riassunto analitico
Project Work 1.4C explores the feasibility of applying additive manufacturing processes to an aeronautical component. Our objective is to establish a general guideline for designing components using additive manufacturing, using two different examples. The first component is a hinge fitting that connects the fixed and moving parts of the vertical tailplane of an ATR aircraft. Due to the demanding load conditions it experiences, this component was initially designed for a metal additive process, specifically using a Titanium alloy with a metal powder deposition technique. The second component is a bracket support for the hydraulic system of an ATR, which facilitates the routing of pipes for the airplane's undercarriage system. Considering the load conditions it must withstand, we opted to base the design on a Fused Deposition Modeling (FDM) production process, utilizing a high- strength polymer called Ultem 9085.
Simulation activity: In this paragraph, we will present the significant steps undertaken during the simulation activity of our work. For both components, the first step involves defining the control volume. In a topology optimization process, this phase is crucial as it determines the maximum mass distribution based on the overall dimensions of the assembly. The software then optimizes by subtracting mass until a satisfactory result is achieved, guided by a target function defined by the maximum stress constraint. Afterwards, following various verification phases outlined in the report, we proceeded to simulate the additive manufacturing process. During this stage, it is essential to gather the most important data, such as residual stress and distortion experienced by the component. These two defects are critical and need to be minimized in the additive manufacturing process. Fortunately, simulations can aid in predicting and compensating for these defects through heat treatment and distortion compensation techniques. We can also simulate these subsequent processes.
Results: The outcomes of our work are manifold, with the most significant result being the guideline presented in a flow chart model and detailed in the final report. Another important achievement is the significant reduction in mass for both the Hinge fitting and the bracket components. The Hinge fitting exhibits a mass reduction of 21%, while the bracket demonstrates a remarkable 71% reduction when compared to their original versions. In this study, our focus was on the processes and steps that an engineer must undertake to optimize and design a component for additive manufacturing. To ensure that the final geometries of the two components possess the same characteristics as the original versions, three crucial subsequent steps need to be executed: fatigue analysis, buckling analysis, and conducting experimental tests to validate the effectiveness of the production process. Furthermore, we have considered only two load case conditions for the dimensioning. For a complete analysis, a broader envelope of dimensioning load conditions should be considered. The latter consideration, along with the buckling and fatigue analysis, could compromise the final mass results.
|
