The objective of this project is to produce an optimized V-22 nacelle link that minimizes the weight while maintaining substantial strength by using topology optimization and additive manufacturing.
Sponsored by: CIMP-3D
Team Members
Siuyeung Cheng Emily Barr Jacob Hersly Bryce Lewis Chenguang Jin
Instructor: Bob Voigt,Timothy Simpson,Eric Goldberg
Project Poster
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Project Video
Project Summary
Overview
The team has been tasked with redesigning the V-22 nacelle link for the MV-22B Osprey helicopter, using additive manufacturing techniques, with the primary objective of cutting weight while maintaining safety and functionality. The new design will be made of Ti-6Al-4V, which must withstand 7600 lbs. of bearing force at 300 degrees F with a factor of safety greater than 1.1. Solidworks was utilized for topology optimization and FEA analysis throughout the process
Objectives
– Demonstrating the advantages of using topology optimization and finite element analysis for additive manufacturing
– Lightweighting the V-22 Osprey’s nacelle link while maintaining substantial strength, using various methods and studies
Approach
– Step 1: Examine the original CAD Part
– Step 2: Apply appropriate boundary conditions
– Step 3: Run initial topology studies
– Step 4: Research and implement lattice structure
– Step 5: Determine minimum thickness using FEA
– Step 6: Run secondary topology studies
– Step 7: Redesign the part
– Step 8: Analyze printing orientations
– Step 9: Run FEA to confirm the results
Outcomes
– 44% mass reduction from the original part
– Final design’s factor of safety reaches 1.14
– Viability of the final design is proved by finite element analysis