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2022 Vol. 65, No. 14
Published: 2022-07-15
FEATURE
FORUM
C0NTENTS
COVER STORY
SPECIAL TOPIC
 
1 COVER
2022 Vol. 65 (14): 1-1 [Abstract] ( 92 ) HTMLNew PDF (2501 KB)  ( 77 )
       C0NTENTS
6 CONTENTS
2022 Vol. 65 (14): 6-10 [Abstract] ( 98 ) HTMLNew PDF (362 KB)  ( 40 )
       FEATURE
14 Integration of Topology Optimization and Additive Manufacturing Technology and Its Application in Civil Aircraft Structural Design
GU Xiaojun，LI Chengbin，WANG Wenlong，ZHOU Lu，ZHU Jihong，ZHANG Weihong
DOI: 10.16080/j.issn1671-833x.2022.14.014
Topology optimization (TO) & additive manufacturing (AM) provide a complete innovation methodology for lightweight and high-performance complicated structures. This paper reviews the recent research on the integration of TO and AM, including the TO method considering AM processing constraints, the optimization method of non-uniform lattice structure. Furthermore, the integration of TO and AM is typically applied in civil aircraft structural design. Taking the structural design of hatch rocker arm and hinge arm as examples, while meeting the design indicators, the weight of hatch rocker arm and hinge arm structure were reduced by 10% and 30%, respectively. Finally, the integration of TO and AM shows obvious advantages in aerospace and other fields. However, the conventional design methods such as traditional static stiffness and static strength are mainly used, currently, and the industry application are focused on functional parts and secondary load-bearing parts. In the future, breakthroughs are needed in the fields such as fatigue-resistant design of AM structures.
2022 Vol. 65 (14): 14-20 [Abstract] ( 319 ) HTMLNew PDF (15949 KB)  ( 196 )
       COVER STORY
22 Research Status and Development Trend of Additive Manufacturing Metamaterials Toward Aerospace
SONG Bo1, ZHANG Lei1, WANG Xiaobo，FAN Junxiang，WEI Shuaishuai，ZHANG Zhi1, LI Jingyang，QI Junfeng，SHI Yusheng
DOI: 10.16080/j.issn1671-833x.2022.14.022
Due to the characteristics of layered manufacturing, additive manufacturing (AM) is an effective means to realize the forming of complex, integrated and personalized high-performance components, which changes the design from process-oriented to performance-oriented design, greatly improves the design space, and has a large application space in aerospace and other fields. To meet the multi-performance requirements of high-end equipment for components,the structural design has developed from lightweight topology optimization design to multi-physics coupling functional structure design and intelligent structure design based on environmental excitation response. Among them, the design and additive manufacturing of multi-physics coupled functional metamaterials is an important development direction.Metamaterials are engineering materials that exhibit special mechanical, acoustic, thermal or electromagnetic properties through macro and micro cross-scale structural design. This paper describes the recent research progress in the field of aerospace structural design and additive manufacturing from the aspects of mechanical metamaterials, functional metamaterials and intelligent metamaterial components. The development trend of structural innovative design and additive manufacturing is summarized and prospected, and the broad application prospect is described.
2022 Vol. 65 (14): 22-33 [Abstract] ( 407 ) HTMLNew PDF (41760 KB)  ( 407 )
       FORUM
36 Research Progress on Design, Optimization and Performance Characterization of Additive Manufactured 3D Lattice Structures
DUAN Shengyu，WANG Panding，LIU Chang，ZHAO Zeang，ZHOU Hao，ZHANG Xiaoyu，LEI Hongshuai，GUO Xu，FANG Daining
DOI: 10.16080/j.issn1671-833x.2022.14.036
Additive manufacturing (AM) technology and three-dimensional (3D) lattice structure technology are important routes toward lightweight multifunctional aerospace equipment. This paper reviews the recent research progress on additive manufactured 3D lattice structures and their design methods, focusing on the status and trends in the following aspects: engineering application of additive manufactured 3D lattice structures, design method of lightweight and multi-functional 3D lattice structures, multi-scale numerical simulation and topology optimization method of 3D lattice structures, mechanical performance evaluation and characterization method of 3D lattice structures for additive manufacturing. Finally, the development trend of material–structure–multifunction integrated design of additive manufactured 3D lattice structures is prospected.
2022 Vol. 65 (14): 36-48/57 [Abstract] ( 436 ) HTMLNew PDF (45986 KB)  ( 221 )
49 Selective Laser Melting Additive Manufacturing of Low Pressure Drop Filter: Design, Manufacturing and Simulation Analysis
WANG Di，FENG Yongwei，YE Guangzhao，YANG Yongqiang，LI Yang，NEIL Burns，WANG Jiachun，HAN Changjun
DOI: 10.16080/j.issn1671-833x.2022.14.049
The advantages of selective laser melting (SLM) for manufacturing industrial fifilters with low resistance, low energy consumption and high filtration performance are analyzed. Explored the design method of gradient porous structure fifilter based on SLM process, and designed the fifiltration with difffferent porosity (60%, 70%, 80% and 90%) under three difffferent units of cross, star and vintiles based on the design rules. Use XFlow software to simulate the pressure drop-flflow experiment of the fifilter, analyze the forming effffect of the fifilter made by SLM, and fifinally carry out the pressure drop test and discuss the flflow of the flfluid when the flfluid passes through the structure. The results show that the gradient porous structure design method realizes a gradient change in the pore size of the fifilter in the radial direction, and the gradient can be adjusted by the number of nodes in each layer. The CFD simulation and pressure drop test shows that the cross structure and the star structure have similar pressure drop performance. The vintiles structure has the lowest pressure drop under the same porosity. The post-processed part pressure drop experiment value deviates from the CFD simulation value by 10%–20%. CFD simulation technology can effffectively predict the pressure drop of the fifilter and prompt the optimization direction of structural flflow resistance.
2022 Vol. 65 (14): 49-57 [Abstract] ( 167 ) HTMLNew PDF (28941 KB)  ( 96 )
58 Additive Manufacturing and Sound Absorption Characterization of Porous Materials
CHEN Wenjiong, CHANG Runxin, WANG Xiaopeng
DOI: 10.16080/j.issn1671-833x.2022.14.058
The preparation method of porous material based on additive manufacturing was studied, and the experimental study on the sound absorption characteristics of the material was carried out. Based on the additive manufacturing technology of fused deposition modeling (FDM), a direct fifilling method which could quickly realize the geometric model of porous materials was constructed. The relationship between the process parameters and the structural parameters of porous materials was established. By setting the process parameters such as thickness of the printed part, fifilling form, fifilling rate, printing line width, printing layer height and layer angle, the key parameters such as thickness, pore structure form, porosity, bar size and angle of the porous materials can be effectively controlled, which avoids the tedious and detailed modeling process of a large number of microstructures. The sound absorption coefficient was measured by double microphone impedance tube. The effffects of thickness, bar size and pore structure of porous material on sound absorption performance were systematically studied. The results show that the porosity (bar spacing) has the most signifificant inflfluence on the sound absorption peak. When the porosity increases from 20% to 30%, the sound absorption peak increases from 0.8 to 0.98. When the porosity increases from 30% to 60%, the sound absorption peak decreases from 0.98 to 0.6. The most obvious inflfluence on the resonant frequency corresponding to the sound absorption peak is the material thickness. When the material thickness increases from 10 mm to 30 mm, the resonant frequency corresponding to the sound absorption peak decreases from 6000 Hz to 1750 Hz. The research work in this paper verififies the feasibility of using additive manufacturing to realize porous materials with accurate geometric characteristics, and opens up a broad way for the customization of porous materials to meet specifific sound absorption performance requirements.
2022 Vol. 65 (14): 58-66 [Abstract] ( 189 ) HTMLNew PDF (14671 KB)  ( 96 )
67 Coaxial 3D-Printing for Low Melting-Point Alloy and Polymer Composites
LI Zhen，LIU Junfeng，FENG Xiangchao，LIU Bingjie，YU Yuan，JIAO Zhiwei，WANG Pengfei
DOI: 10.16080/j.issn1671-833x.2022.14.067
In order to develop the process of metal/polymer 3D printing, a coaxial 3D printing device for molding low melting-point alloys and polymer composites was designed. Driven by a piston extruder and heated with heating systems, alloys and polymer composites are extruded through the nested coaxial nozzle, thus continuously integrated and molded into 3D printed composite components with better mechanical properties. In addition, the process parameters such as extrusion pressure, temperature and speed are simulated by fifinite element method and the inflfluence of printing speed, temperature, viscosity and other parameters is explored under experiments to optimize the printing process. Finally, the feasibility of such device and process is verifified in practice, which exhibits a possible method for the 3D printing of low melting-point alloy and polymer composites.
2022 Vol. 65 (14): 67-78 [Abstract] ( 178 ) HTMLNew PDF (47968 KB)  ( 88 )
       SPECIAL TOPIC
80 Design and Manufacturing of Pentamode Acoustic Wave Manipulation Devices: A Review
ZHAO Aiguo，ZOU Han，ZHAO Zhigao，ZHANG Mangong，CHEN Hong，WANG Zhen，ZHANG Xiangdong
DOI: 10.16080/j.issn1671-833x.2022.14.080
Pentamode materials are special solid materials mimicking complex flfluid, which could achieve desired mechanical properties through microstructure design of conventional solids. Tunable mechanical properties and solid merit endow pentamode materials with prospective application in broadband underwater acoustic wave manipulation such as acoustic cloaking and focusing, which stimulates an intense research activity recently. In this review, basic concept of pentamode materials and the status of microstructure design were introduced firstly, then the corresponding devices fabrication and experimental verifification based on conventional manufacturing techniques and additive manufacturing are illustrated elaboratively, and the technical demanding and trending is proposed fifinally.
2022 Vol. 65 (14): 80-91 [Abstract] ( 185 ) HTMLNew PDF (50408 KB)  ( 120 )
92 Study on Mechanical Response of Selective Laser Melted Nickel-Titanium Based Pentamode Metamaterials
ZHANG Lei，WEI Shuaishuai，SONG Bo，LI Jingyang，ZHANG Jianchao，QI Junfeng，SHI Yusheng
DOI: 10.16080/j.issn1671-833x.2022.14.092
Pentamode metamaterials (PMs) have uncoupled relative density and mechanical properties, which have potential applications in the field of special acoustic equipments and biological implants. Selective laser melting (SLM) technology has the ability to form complex and fifine lattice metamaterials, which can achieve customized stiffffness, controllable cell topology, cell size and porosity. In this work, nickel-titanium shape memory alloy (NiTi SMA) powder was used to fabricate pentamode metamaterials with difffferent topological shapes by selective laser melting. The observation results of micro-morphology show that the nickel-titanium based pentamode metamaterials formed by SLM has good manufacturing fifidelity. The fifinite element simulation is used to predict the stress distribution in the compression process of the pentamode metamaterial, and it is found that the stress is concentrated in the joint of the struts. The experimental results of compression mechanics show that the strength of NiTi based pentamode metamaterial increases with the increase of relative density. By establishing the mathematical models of relative density, relative modulus and strength, the mechanical properties of pentamode metamaterials with difffferent relative densities can be well predicted.
2022 Vol. 65 (14): 92-100/109 [Abstract] ( 161 ) HTMLNew PDF (25969 KB)  ( 93 )
101 Mechanical Properties of Topologically Lightweight Conical Components Fabricated by Laser Additive Manufacturing
LIN Kaijie，WU Libin，YANG Jiankai，ZHANG Han，GU Dongdong
DOI: 10.16080/j.issn1671-833x.2022.14.101
Aerospace lightweight structures usually need to meet various performance requirements, such as weight reduction, load-bearing, shock absorption and impact resistance. However, the weight reduction of structures is often accompanied by the reduction of load-bearing and impact resistance. In this paper, the topology optimization design of conical structures was carried out based on variable density method. And the integrated forming of conical lightweight components was realized by laser powder bed melting technology. The inflfluence mechanism of wall thickness on the mechanical properties of topologically optimized components under axial compression were studied. As the wall thickness increased from 1.0 mm to 3.0 mm, the specifific energy absorption increased fifirstly and then decreased. The component with wall thickness of 2.5 mm exhibited the highest specifific energy absorption, which was 11.48 J/g. The stress distribution during compression was studied by fifinite element simulation, which showed that the main reason for the buckling and fracture of structures was the large in plane compressive stress. The difffference of stress levels between the inner and outer walls led to the buckling deformation of the structure in difffferent directions. And with the increase of wall thickness, the stress concentration at the top of the cone and the reduction of the upper buckling degree terminated the continuous increase of energy absorption.
2022 Vol. 65 (14): 101-109 [Abstract] ( 196 ) HTMLNew PDF (13505 KB)  ( 236 )
110 Design of Lightweight Multi-Lattice Structure and Mechanical Property Analysis of Transition Boundaries
LIU Tingting, LIANG Zhuoheng, REN Fangxi, LIAO Wenhe, ZHANG Changdong, LI Dawei
DOI: 10.16080/j.issn1671-833x.2022.14.110
The fusion design method based on multi-lattice is expected to bring a new approach to weight reduction and increase performance of aerial structures. The existing design methods of multi-lattice structure have some problems, such as very small rod diameter, topology discontinuity and weak bearing capacity. An optimal design strategy of multi-lattice transition interface based on substructure parameter regulation was proposed. By adjusting the connectivity of transition region of different lattice configurations, the geometric high-order continuous optimization of multi-lattice transition boundary was realized. On this basis, the inflfluence of difffferent arrangement modes on deformation behavior and load-bearing capacity of multi-lattice structure was further analyzed, and the theoretical prediction model of geometric parameters-performance of multi-lattice structure was established. Experimental results show that compared with the traditional multi-lattice design method, the structural strength of the proposed method is improved by 52.2%. In addition, reasonable interface morphology can effffectively transfer load and avoid catastrophic failure of the structure at the interface.
2022 Vol. 65 (14): 110-117 [Abstract] ( 232 ) HTMLNew PDF (39647 KB)  ( 168 )
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