Abstract
The application of a lattice structure in the lightweight design of compressor impellers can reduce their mass and moment of inertia, hence improving the effective carrying of aircraft and reducing the start and braking moments of the impeller. The feasibility of a processing-lattice compressor impeller is the prerequisite for its application. To control the residual deformation and residual stress effectively, a computer-aided design technique is used to simulate the manufacturing process of a compressor impeller. The residual deformation and stress of the compressor impeller during the additive manufacturing process is calculated. The material-stacking process and base-plate- and support-removal process of a TiAl6V4 impeller printed by an SLM280 metal 3D printer are simulated by the finite-element method. The results show that some change in the laser printing parameters leads to a significant impact on the residual stress and deformation amplitude of the impeller. The residual deformation and residual stress of the lattice compressor impeller with the same geometrical appearance after processing are less than the corresponding amplitude of the solid compressor impeller, which also shows that the printed lattice compressor impeller can more easily achieve the design requirements.
Highlights
The application of a lattice structure in the lightweight design of compressor impellers can reduce their mass and moment of inertia, improving the effective carrying of aircraft and reducing the start and braking moments of the impeller
Such mechanisms include aerospace structures based on topology optimization[7,8] and functional gradient lattice structures based on topology optimization[15,16,17]
The TiAl6V4 impeller is printed with a SLM280 Metal 3D Printer, a 3D scanner is used to scan the printed impeller, and the numerical geometry model of solid impeller is established based on the obtained point-cloud data
Summary
After the lightweight design of the lattice impeller is completed, the 3D-printing process of the impeller is simulated by a numerical method, and the effect of the printing parameters on the residual deformation and stress of the impeller is studied. The residual deformation and stress of the lattice and solid compressor impellers after finishing the printing operation and removing the base plate and support at different working conditions. In the case of the current research, the residual stress of the lattice compressor impeller can be reduced by 8.72% compared with that of solid compressor impeller. For the manufacturing of lattice compressor impeller, the combination of 3-D printing and milling can be considered
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