Abstract
In the aerospace industry, structures are designed (or aimed) to be as light as possible to reduce emissions and carbon footprint; additionally, they are designed to improve fuel efficiency and service life while satisfying the mechanical requirements. Due to the development of additive manufacturing technology, complex structures with higher mechanical performance obtained through topology optimization (TO) can be manufactured. In this study, the overall process from part selection to qualification for a space industry-engineering application is described. First, the design space of the selected aluminum bracket is generated, and TO is performed by using stress and minimum member size constraints. The bracket is re-designed with respect to the TO output data as a reference and then the new design is validated numerically by structural analyses. The validated design is manufactured using the selective laser melting method, and heat treatment is applied to obtain more homogenized microstructure. Mechanical tests are performed on the manufactured brackets under the qualification loading conditions and post-testing examination processes are applied with metallurgical and metrological tests. According to the test results, the qualification process of the bracket is successfully completed. Consequently, the new bracket designed with TO was found to be 25% lighter than the existing design; thus, it has a huge improvement in fuel efficiency and environmental impact during the launching phase.
Similar content being viewed by others
References
Allevi G, Cibeca M, Fioretti R, Marsili R, Montanini R, Rossi G (2018) Qualification of additively manufactured aerospace brackets: a comparison between thermoelastic stress analysis and theoretical results. Measurement 126:252–258. https://doi.org/10.1016/J.MEASUREMENT.2018.05.068
Altair University (2018) Practical Aspects of Structural Optimization a Study Guide. https://altairuniversity.com/freeebooks/free-ebook-practical-aspects-of-structural-optimization-a-study-guide/. Accessed 11 Jun 2022
Bendsøe MP, Kikuchi N (1988) Generating optimal topologies in structural design using a homogenization method. Comput Methods Appl Mech Eng 71:197–224. https://doi.org/10.1016/0045-7825(88)90086-2
Bombardieri R, Cavallaro R, Sanchez R, Gauger NR (2021) Aerostructural wing shape optimization assisted by algorithmic differentiation. Struct Multidisc Optim 64:739–760. https://doi.org/10.1007/s00158-021-02884-5
Braga DFO, Tavares SMO, Da Silva LFM, Moreira PM, De Castro PM (2014) Advanced design for lightweight structures: review and prospects. Prog Aerosp Sci 69:29–39. https://doi.org/10.1016/J.PAEROSCI.2014.03.003
Brujic D, Ristic M, Mattone M, Maggiore P, De Poli GP (2010) CAD based shape optimization for gas turbine component design. Struct Multidisc Optim 41:647–659. https://doi.org/10.1007/s00158-009-0442-9
Bruyneel M, Duysinx P (2005) Note on topology optimization of continuum structures including self-weight. Struct Multidisc Optim 29:245–256. https://doi.org/10.1007/s00158-004-0484-y
Chen X, Yao W, Zhao Y, Chen X, Zheng X (2018) A practical satellite layout optimization design approach based on enhanced finite-circle method. Struct Multidisc Optim 58:2635–2653. https://doi.org/10.1007/s00158-018-2042-z
ECSS Secretariat (2004) Space engineering—spacecraft mechanical loads analysis handbook. ESA Requirements and Standards Division, Noordwijk
Edke MS, Chang KH (2006) Shape optimization of heavy load carrying components for structural performance and manufacturing cost. Struct Multidisc Optim 31:344–354. https://doi.org/10.1007/s00158-005-0603-4
Gasman L (2019) Additive aerospace considered as a business. Additive manufacturing for the aerospace industry. Elsevier, Amsterdam, pp 327–340
Gradl PR, Greene SE, Protz C, Bullard B, Buzzell J, Garcia C, Wood J, Osborne R, Hulka J, Cooper KG (2018) Additive manufacturing of liquid rocket engine combustion devices: a summary of process developments and hot-fire testing results. Jt Propuls Conf 2018:1–34. https://doi.org/10.2514/6.2018-4625
Grihon S, Bassir D, Krog L (2009) Numerical optimization applied to structure sizing at AIRBUS: a multi-step process. Int J Simul Multidiscip Des Optim. https://doi.org/10.1051/ijsmdo/2009020
Ide T, Otomori M, Leiva JP, Watson BC (2014) Structural optimization methods and techniques to design light and efficient automatic transmission of vehicles with low radiated noise. Struct Multidisc Optim 50:1137–1150. https://doi.org/10.1007/s00158-014-1143-6
Koelle DE (2003) Specific transportation costs to GEO—past, present and future. Acta Astronaut 53:797–803. https://doi.org/10.1016/S0094-5765(03)80032-2
Lee DS, Fahey DW, Forster PM, Newton PJ, Wit RC, Lim LL, Owen B, Sausen R (2009) Aviation and global climate change in the 21st century. Atmos Environ 43:3520–3537. https://doi.org/10.1016/J.ATMOSENV.2009.04.024
Liu K, Tovar A (2014) An efficient 3D topology optimization code written in Matlab. Struct Multidisc Optim 50:1175–1196. https://doi.org/10.1007/s00158-014-1107-x
Munk DJ, Auld DJ, Steven GP, Vio GA (2019) On the benefits of applying topology optimization to structural design of aircraft components. Struct Multidisc Optim 60:1245–1266. https://doi.org/10.1007/s00158-019-02250-6
Nazir A, Jeng JY (2020) A high-speed additive manufacturing approach for achieving high printing speed and accuracy. Proc Inst Mech Eng C 234:2741–2749. https://doi.org/10.1177/0954406219861664
Nazir A, Abate KM, Kumar A, Jeng JY (2019) A state-of-the-art review on types, design, optimization, and additive manufacturing of cellular structures. Int J Adv Manuf Technol 104:3489–3510. https://doi.org/10.1007/s00170-019-04085-3
Orme ME, Gschweitl M, Ferrari M, Madera I, Mouriaux F (2017a) Designing for additive manufacturing: Lightweighting through topology optimization enables lunar spacecraft. J Mech Des Trans ASME 139:1–6. https://doi.org/10.1115/1.4037304
Orme ME, Gschweitl M, Ferrari M, Vernon R, Madera IJ, Yancey R, Mouriaux F (2017b) Additive manufacturing of lightweight, optimized, metallic components suitable for space flight. J Spacecr Rockets 54:1050–1059. https://doi.org/10.2514/1.A33749
Orme M, Madera I, Gschweitl M, Ferrari M (2018) Topology optimization for additive manufacturing as an enabler for light weight flight hardware. Designs 2:51. https://doi.org/10.3390/designs2040051
Remouchamps A, Bruyneel M, Fleury C, Grihon S (2011) Application of a bi-level scheme including topology optimization to the design of an aircraft pylon. Struct Multidisc Optim 44:739–750. https://doi.org/10.1007/s00158-011-0682-3
Ruess F, Segelke H, Abt F, Moratto C, Sansegundo M (2016) Acoustic analysis and testing of the Hispasat AG1 satellite proto-flight model. In: European conference on spacecraft structures, materials and environmental testing SSMET. Toulouse
Savsani VJ, Tejani GG, Patel VK, Savsani P (2017) Modified meta-heuristics using random mutation for truss topology optimization with static and dynamic constraints. J Comput Des Eng 4:106–130. https://doi.org/10.1016/j.jcde.2016.10.002
Shi G, Guan C, Quan D, Wu D, Tang L, Gao T (2020) An aerospace bracket designed by thermo-elastic topology optimization and manufactured by additive manufacturing. Chin J Aeronaut 33:1252–1259. https://doi.org/10.1016/j.cja.2019.09.006
Sigmund O (2007) Morphology-based black and white filters for topology optimization. Struct Multidisc Optim 33:401–424. https://doi.org/10.1007/s00158-006-0087-x
Stolt R, Elgh F (2020) Introducing design for selective laser melting in aerospace industry. J Comput Des Eng 7:489–497. https://doi.org/10.1093/jcde/qwaa042
Talay E, Özkan C, Gürtaş E (2021) Designing lightweight diesel engine alternator support bracket with topology optimization methodology. Struct Multidisc Optim 63:2509–2529. https://doi.org/10.1007/s00158-020-02812-z
Weigel AL, Hastings DE (2004) Evaluating the cost and risk impacts of launch choices. J Spacecr Rockets 41:103–110. https://doi.org/10.2514/1.9270
Zhu JH, Hou J, Zhang WH, Li Y (2014) Structural topology optimization with constraints on multi-fastener joint loads. Struct Multidisc Optim 50:561–571. https://doi.org/10.1007/s00158-014-1071-5
Zhu JH, Li Y, Zhang WH, Hou J (2016a) Shape preserving design with structural topology optimization. Struct Multidisc Optim 53:893–906. https://doi.org/10.1007/s00158-015-1364-3
Zhu JH, Zhang WH, Xia L (2016b) Topology optimization in aircraft and aerospace structures design. Arch Comput Methods Eng 23:595–622. https://doi.org/10.1007/s11831-015-9151-2
Zhu L, Li N, Childs PRN (2018) Light-weighting in aerospace component and system design. Propuls Power Res 7:103–119. https://doi.org/10.1016/j.jppr.2018.04.001
Zhu J, Zhou H, Wang C, Zhou L, Yuan S, Zhang W (2021) A review of topology optimization for additive manufacturing: status and challenges. Chin J Aeronaut 34:91–110. https://doi.org/10.1016/j.cja.2020.09.020
Zhuang C, Xiong Z, Ding H (2021) Temperature-constrained topology optimization of nonlinear heat conduction problems. J Comput Des Eng 8:1059–1081. https://doi.org/10.1093/jcde/qwab032
Acknowledgements
The authors acknowledge the support of Turkish Aerospace for providing test facilities. This study is a part of the project (# 5189901) supported by The Scientific and Technological Research Council of Turkey (TÜBİTAK) under the Frontier R&D Laboratory Support Program and performed in Turkish Aerospace Industries Inc.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Replication of results
Loading conditions, boundary conditions and material properties of the bracket are given in Tables 1, 2 and 3, respectively. The finite element model of the bracket is confidential for the company. Additionally, the equipment qualification level is confidential and protected. The results provided herein are replicable with a similar output of topology optimization using the same inputs and the same optimization problem.
Additional information
Responsible Editor: Axel Schumacher
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Appendix
Appendix
Images about the vibro-acoustic analysis setup, shock test setup/instrumentation and applied shock load during time transient analyses are given in Fig. 28.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Gökdağ, İ., İzgü, O., Dağkolu, A. et al. Design optimization and validation for additive manufacturing: a satellite bracket application. Struct Multidisc Optim 65, 237 (2022). https://doi.org/10.1007/s00158-022-03345-3
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s00158-022-03345-3