Combining Macro- and Mesoscale Optimization: A Case Study of the General Electric Jet Engine Bracket

Evangelos Tyflopoulos,Martin Steinert

doi:10.3390/designs5040077

Evangelos Tyflopoulos, Martin Steinert

Open Access

https://doi.org/10.3390/designs5040077

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Journal: Designs	Publication Date: Dec 2, 2021
Citations: 1	License type: CC BY 4.0

Affiliation: Norwegian University of Science and Technology

Abstract

Topology optimization (TO) is a mathematical method that optimizes the material layout in a pre-defined design domain. Its theoretical background is widely known for macro-, meso-, and microscale levels of a structure. The macroscale TO is now available in the majority of commercial TO software, while only a few software packages offer a mesoscale TO with the design and optimization of lattice structures. However, they still lack a practical simultaneous macro–mesoscale TO. It is not clear to the designers how they can combine and apply TO at different levels. In this paper, a two-scale TO is conducted using the homogenization theory at both the macro- and mesoscale structural levels. In this way, the benefits of the existence and optimization of mesoscale structures were researched. For this reason, as a case study, a commercial example of the known jet engine bracket from General Electric (GE bracket) was used. Different optimization workflows were implemented in order to develop alternative design concepts of the same mass. The design concepts were compared with respect to their weight, strength, and simulation time for the given load cases. In addition, the lightest design concept among them was identified.

Highlights

In the literature, the structure of a component can be categorized with respect to its physical size, from bigger to smaller, and to macro, meso, and microscale structures [1].there are no specific size limits that separate one from the other
The design solutions were compared for maximum weight reduction
A research study of the cubic cell type and cell orientation was conducted in the third step

Summary

Introduction

The structure of a component can be categorized with respect to its physical size, from bigger to smaller, and to macro-, meso-, and microscale structures [1].there are no specific size limits that separate one from the other. The structure of a component can be categorized with respect to its physical size, from bigger to smaller, and to macro-, meso-, and microscale structures [1]. The macroscale is considered the external layout of a structure, while its infill is the mesoscale structure. The elements that constitute the infill are usually unit cells creating a periodically ordered pattern [2]. The structure of the unit cells is a good example of a microscale structure. It is assumed that the continuum mechanics can be applied to the macro-, meso-, and microscale levels of a structure [1].

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