Abstract
Recent levels of structural integrity of components built in the Aeroswift high-speed laser powder bed fusion machine have led to the decision to produce a structural aircraft component through this technology. The Aeroswift machine is capable of building larger Ti6Al4V parts at a more rapid pace than current commercial laser metal powder bed fusion systems. As prototype component, the nose-wheel fork of the AHRLAC aircraft, which was conventionally machined in aluminum alloy 7050, was selected. This paper describes the design, topology optimisation and the manufacturing approach taken in this project. Given the design space, loads, strength requirements and boundary conditions prescribed by the AHRLAC engineers, topology optimisation was performed on the nose-wheel fork to design a lightweight component for production in Ti6Al4V. Different topology optimisation software suites were used, to establish their capabilities and fit-for-purpose features. The optimised design and percentage of weight saving are presented. An assessment based on the experience with the different software suites is offered.
Highlights
AHRLAC (Advanced High Performance Reconnaissance Light Aircraft) is an unusual two-person cockpit pusher propeller plane, designed by engineers of the South African company Aerosud and manufactured in partnership between the Paramount Group and Aerosud
This paper evaluated the capability and fit-for-purpose feature of the topology optimisation software used for the redesign of the AHRLAC nose-wheel fork
The nose-wheel fork of the AHRLAC, which was conventionally machined from Al 7050 and is 8,23 kg in weight, was redesigned using topology optimisation software
Summary
AHRLAC (Advanced High Performance Reconnaissance Light Aircraft) is an unusual two-person cockpit pusher propeller plane, designed by engineers of the South African company Aerosud and manufactured in partnership between the Paramount Group and Aerosud. The Aeroswift high-speed laser powder bed fusion machine was designed to manufacture metallic parts from alloy powders, such as titanium and stainless steel [1] [3]. Low-density elements experience high levels of stress and are not removed from the design domain [7] In this way the optimal shape (load path) is generated from the optimisation software. The combination of topology optimisation with AM of Ti6Al4V (ELI) could advance saving production cost and ensuring positive production in aviation industries [12] This intriguing use of metal AM for production of aircraft structural parts presents great challenges to the designer. The conventional method of producing aircraft structural parts, topology optimisation design for additive manufacturing (DfAM) practices are not sufficiently understood nor characterised for production of aircraft structural parts [13]. This paper evaluated the capability and fit-for-purpose feature of the topology optimisation software used for the redesign of the AHRLAC nose-wheel fork
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