Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation
The integration of topology optimization into additive manufacturing provides unmatched possibilities for the sustainable manufacturing of lightweight, intricate, custom parts with less material at a lower production time and cost. This study aims to apply and benchmark topology optimization methods...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-12-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/13/24/13218 |
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| author | Onyekachi Okorie Asma Perveen Didier Talamona Konstantinos Kostas |
| author_facet | Onyekachi Okorie Asma Perveen Didier Talamona Konstantinos Kostas |
| author_sort | Onyekachi Okorie |
| collection | DOAJ |
| description | The integration of topology optimization into additive manufacturing provides unmatched possibilities for the sustainable manufacturing of lightweight, intricate, custom parts with less material at a lower production time and cost. This study aims to apply and benchmark topology optimization methods, in conjunction with additive manufacturing, to enhance the design of functional components used in aerospace applications, while simultaneously providing an experimental verification and comparative analysis of such optimization techniques. This approach was applied to an industrial bracket used in aerospace applications, which was optimized with the aim of weight reduction without sacrificing its original mechanical stiffness. A density-based technique and a level-set method were used to perform the analysis and optimization, whereas fabrication was performed using fused deposition modeling. Finally, a compression and tensile testing machine was employed for the testing, verification, and comparison of the exhibited mechanical strength for the whole range of printed parts, under the same load conditions. The optimized designs achieved a 20% weight reduction while maintaining the compression displacement of the initial components at the given load. The achieved results demonstrate that topologically optimized components can significantly enhance the design of real-life components, such as those used in the weight-sensitive industrial applications considered in this work. |
| first_indexed | 2024-03-08T21:01:21Z |
| format | Article |
| id | doaj.art-24c7fbe1620449c1ad737621e5d9a55f |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-08T21:01:21Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-24c7fbe1620449c1ad737621e5d9a55f2023-12-22T13:51:54ZengMDPI AGApplied Sciences2076-34172023-12-0113241321810.3390/app132413218Topology Optimization of an Aerospace Bracket: Numerical and Experimental InvestigationOnyekachi Okorie0Asma Perveen1Didier Talamona2Konstantinos Kostas3Department of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana 010000, KazakhstanDepartment of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana 010000, KazakhstanDepartment of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana 010000, KazakhstanDepartment of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana 010000, KazakhstanThe integration of topology optimization into additive manufacturing provides unmatched possibilities for the sustainable manufacturing of lightweight, intricate, custom parts with less material at a lower production time and cost. This study aims to apply and benchmark topology optimization methods, in conjunction with additive manufacturing, to enhance the design of functional components used in aerospace applications, while simultaneously providing an experimental verification and comparative analysis of such optimization techniques. This approach was applied to an industrial bracket used in aerospace applications, which was optimized with the aim of weight reduction without sacrificing its original mechanical stiffness. A density-based technique and a level-set method were used to perform the analysis and optimization, whereas fabrication was performed using fused deposition modeling. Finally, a compression and tensile testing machine was employed for the testing, verification, and comparison of the exhibited mechanical strength for the whole range of printed parts, under the same load conditions. The optimized designs achieved a 20% weight reduction while maintaining the compression displacement of the initial components at the given load. The achieved results demonstrate that topologically optimized components can significantly enhance the design of real-life components, such as those used in the weight-sensitive industrial applications considered in this work.https://www.mdpi.com/2076-3417/13/24/13218additive manufacturingtopology optimizationlevel-set methoddensity-based method |
| spellingShingle | Onyekachi Okorie Asma Perveen Didier Talamona Konstantinos Kostas Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation Applied Sciences additive manufacturing topology optimization level-set method density-based method |
| title | Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation |
| title_full | Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation |
| title_fullStr | Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation |
| title_full_unstemmed | Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation |
| title_short | Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation |
| title_sort | topology optimization of an aerospace bracket numerical and experimental investigation |
| topic | additive manufacturing topology optimization level-set method density-based method |
| url | https://www.mdpi.com/2076-3417/13/24/13218 |
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