Search Results (2)

In order to solve the design requirements of high stiffness and lightweight for the primary support structure of a wide-field auroral imager, we propose a solution for designing and optimizing a large-scale complex thin-walled structure using additive manufacturing. Firstly, we devise an integrated thin-walled structure and test material for the main support. Secondly, shape optimization is achieved via the optimization of the lateral slope angle of the primary support based on Timoshenko cantilever beam theory. Additionally, an active fitting optimization algorithm is proposed for the purpose of refining the wall thickness of the thin-walled structure. Then, we determine the structural design of the main support. This primary support is manufactured via selective laser melting (SLM). Following processing, the structure size is 538 mm × 400 mm × 384 mm, and the mass is 7.78 kg. Finally, frequency scanning experiments indicate that, in the horizontal direction, there is a natural frequency of 105.97 Hz with an error rate of approximately 3% compared to finite element analysis results. This research confirms that our large-scale complex, thin-walled main support structure design meets all design requirements. Full article

In the aerospace field, lightweight design is a never-ending pursuit. By integrating structural bionics and structural optimization, the vertical bracket of a wide angle auroral imager is designed and manufactured by additive manufacturing technology in this work. Initially, the classical topology optimization is utilized for the vertical bracket to find the optimal material layout and primary load carrying paths. Drawing on the width-to-diameter ratio and the bone mineral density distribution of human femur, the vertical support is designed as a bionic structure with a solid middle section and thin wall in other parts. Afterwards, size optimization is maintained for the bionic design model to obtain the optimal model. The simulation results show that the three-way eigenfrequencies of bionic optimized structure are 320 Hz, 303 Hz, and 765 Hz, respectively, which are closely approximate to the original structure. However, the mass of bionic optimized structure is reduced by 23%. Benefiting from Selective laser melting, the complex optimized design can be rapidly manufactured. The three-way eigenfrequencies of the optimized structure measured by the 0.2 g sweep tests are 307 Hz, 292 Hz, and 736 Hz, respectively. The vibration test of bionic optimized structure verifies the accuracy of the simulation results. This study indicates that the combination of structural bionics and structural optimization provides a powerful tool kit to the design of similar support structure for space applications. Full article