Topology Optimization Design of Impellers Based on Selective Laser Melting Process

Senpeng Fang; Weihao Chen; Dan Huang; Ruiwen Chen; Fuqiang Huang

doi:10.54097/zfzzas93

Authors

Senpeng Fang
Weihao Chen
Dan Huang
Ruiwen Chen
Fuqiang Huang

DOI:

https://doi.org/10.54097/zfzzas93

Keywords:

Additive Manufacturing, Finite Element Analysis, Topology Optimization, Equivalent Stress

Abstract

Aiming at the core contradiction between structural strength and material weight reduction in the lightweight design of impellers, this paper proposes a topology optimization method considering support-free forming and blade geometric shape retention based on selective laser melting (SLM) additive manufacturing technology. The variable density method is adopted for topology optimization design, and hollow structures and lattice filling strategies are integrated to optimize the internal material distribution of impellers. SLM process constraints are introduced in the optimization process to ensure that components can be formed without additional support structures. Static mechanical performance verification of the optimized model is conducted via finite element analysis. The results show that the overall weight of the optimized model is reduced by 36% while satisfying the requirements of impeller overall dimensions and mechanical properties, which effectively balances lightweight demand, structural strength and forming process adaptability.

Downloads

Download data is not yet available.

References

[1] Yu H, Yang H B, Mao J, et al. Structural topology optimization based on SIMP variable density method and its application[J]. Engineering Plastics Application, 2024, 52(10): 91-99.

[2] Liang K X, Zhu D C, Li F Y. A Fourier neural operator-based lightweight machine learning framework for topology optimization[J]. Applied Mathematical Modelling, 2024, 129: 714-728.

[3] Ge W J, Zhu P G, Liu S L, et al. Exploring further multi-objective optimization for shape change of aircraft leading edge using compliant mechanisms[J]. Journal of Northwestern Polytechnical University, 2010, 28(2): 211-215.

[4] Thompson D J, Feys J, Filewich M D, et al. The design and construction of a blended wing body UAV[C]//49th AIAA Aerospace Sciences Meeting Including the New Horizons Forum and Aerospace Exposition. Orlando: AIAA, 2011: 841.

[5] Paz J, Díaz J, Romera L, et al. Size and shape optimization of aluminum tubes with GFRP honeycomb reinforcements for crashworthy aircraft structures[J]. Composite Structures, 2015, 133: 499-507.

[6] Cavazzuti M, Costi D, Baldini A, et al. Automotive chassis topology optimization: A comparison between spider and coupé designs[C]//Proceedings of the World Congress on Engineering. London: IAENG, 2011.

[7] Ko H Y, Shin K B, Jeon K W, et al. A study on the crashworthiness and rollover characteristics of low-floor bus made of sandwich composites[J]. Journal of Mechanical Science and Technology, 2009, 23(10): 2686-2693.

[8] Wei W B. Research on topology optimization design of a folding scooter pedal bracket[J]. Light Alloy Fabrication Technology, 2023, 51(11): 57-62.

[9] Kranz J, Herzog D, Emmelmann C. Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4[J]. Journal of Laser Applications, 2015, 27(S1): S14001.