🏆 Best Project 3rd Place

The objective of this project is to utilize a combination of topology optimization software tools and AM processes to lightweight a helicopter component.

 

 

Team Members

Daniel Carrieri    Gokce Necioglu    Joshua Alwine    Ram Aryan Movalla    Abhishek Patel                     

Instructor: Charlie Purdum, El-Amine Lehtihet

 

Project Poster

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Project Video

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Project Summary

Overview

In 2016, the U.S. Navy flew their first flight-critical component made with metal additive manufacturing (AM) on the MV-22B Osprey Helicopter. They collaborated with NAVAIR and CIMP-3D to support the AM builds for these flight-critical components. CIMP-3D is now looking to optimize the weight of these components while maintaining structural integrity and manufacturability. Our team was tasked with lightweighting a V-22 nacelle link using topology optimization software tools and AM processes.

Objectives

-Utilize a combination of topology optimization software tools and AM processes to lightweight the part to around 50% of the original weight.

– Compare results for four different material options: Ti-6Al-4V, AlSi10Mg, SS 316L, and IN718.

-Produce 3D printed polymer prototypes.

-Develop a final design that is suitable for fabrication using a laser powder-bed fusion (LPBF) system.

Approach

Three phase optimization approach

Phase 1: Initialization
– Select topology optimization and FEA software (nTopology and SOLIDWORKS).

– Identify boundary/loading conditions based on provided literature and additional research.

– Run initial topology tests to identify challenges and refine boundary/loading conditions.

Phase 2: Optimization Testing
Run topology optimization tests for each material.
– Apply loads to the part and identified critical points.

– Based on critical points, select regions to remove material

Rebuilding
– Rebuild the part based on topology optimization results.

– Iterate multiple design concepts.

FEA testing
– Perform static loading tests based on loading conditions.

– Report results.

Repeat
– This testing process was repeated for each of the ten developed part iterations.

Phase 3: Data Analysis and Prototyping
– Compare data for each of the developed iterations.

– Select the top design concept as the Alpha Prototype and 3D print a polymer prototype.

– Receive feedback from sponsors on the Alpha Prototype.

– Utilize feedback and additional testing to fully optimize the Alpha Prototype

– Finalize testing to develop a final Beta Prototype and 3D print a polymer prototype.

Outcomes

– Our final prototype is 66.38 grams which is a 46% weight reduction from the original part. Also, it passed the optimal static test in which the part was loaded at 125% of the optimal load (33,806 N).

– Ti-Al6-4V was chosen as the optimal material due to its ability to withstand the required load while maintaining a relatively light weight.

– Our final prototype is also fit to be printed via laser powder-bed fusion, which demonstrates the advantages of combining topology optimization software tools with AM processes.