TOPOLOGY AND SHAPE OPTIMIZATION OF A MOUNT LINK CONSIDERING LOCAL MICROSTRUCTURE-DEPENDENT FATIGUE PROPERTIES OBTAINED FROM FORMING SIMULATIONS

TOPOLOGY AND SHAPE OPTIMIZATION OF A MOUNT LINK CONSIDERING LOCAL MICROSTRUCTURE-DEPENDENT FATIGUE PROPERTIES OBTAINED FROM FORMING SIMULATIONS

Maderbacher, H.; Wagner, C.; Oberwinkler, B.; Gänser, H.-P.; Riedler, M.

Full Article:

In times of increasing costs for energy and natural resources together with the aim of getting environmental pollution under control, light weight design is of paramount importance today. Light weight design always goes along with the best possible knowledge of the used material’s behavior, the influencing boundary and environmental conditions as well as the loading in service to ensure the component’s fitness for purpose. As an example of lightweight design the dimensioning and fatigue lifetime evaluation of a hot forged Ti-6-4 aerospace engine mount link shall be considered in what follows. In the first step, a topology and shape optimization is used for stress minimization. Two design proposals are retained; one having maximum fatigue life, the other having least weight. In the next step, the optimized geometries as well as the original mount link are analyzed in a finite element (FE) simulation to get the stress results in each node. The fatigue lifetime estimation is performed by means of a special purpose post-processor taking into account the influence of the local microstructure as obtained from the forming simulation. These data are used to compare weight and fatigue lifetime of the original and the optimized geometries. Finally, the optimized components are manufactured and tested to verify the computational method.

In times of increasing costs for energy and natural resources together with the aim of getting environmental pollution under control, light weight design is of paramount importance today. Light weight design always goes along with the best possible knowledge of the used material’s behavior, the influencing boundary and environmental conditions as well as the loading in service to ensure the component’s fitness for purpose. As an example of lightweight design the dimensioning and fatigue lifetime evaluation of a hot forged Ti-6-4 aerospace engine mount link shall be considered in what follows. In the first step, a topology and shape optimization is used for stress minimization. Two design proposals are retained; one having maximum fatigue life, the other having least weight. In the next step, the optimized geometries as well as the original mount link are analyzed in a finite element (FE) simulation to get the stress results in each node. The fatigue lifetime estimation is performed by means of a special purpose post-processor taking into account the influence of the local microstructure as obtained from the forming simulation. These data are used to compare weight and fatigue lifetime of the original and the optimized geometries. Finally, the optimized components are manufactured and tested to verify the computational method.

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DOI: 10.5151/meceng-wccm2012-18748

Referências bibliográficas

• [1] European Aviation Security Agency, Certification Specifications for Large Aeroplanes (CS-25), Subpart C Amendment 5, 2008
• [2] http://www.techcomp.at
• [3] May S., Titanium Fitting investigation, Report Nr. CIV09/077/01, Stainz, October 2009
• [4] Oberwinkler B., Fatigue-Proof and Damage Tolerant Lightweight Design of Ti-6Al-4V Forgings, Doctoral Thesis, Montanuniversität Leoben, April 2010
• [5] Schütz D.; Lowak H.; de Jonge J.B.; Schijve J.: Standardisierter Einzelflug- Belastungsablauf für Schwingfestigkeitsversuche an Tragflächenbauteilen von Transportflugzeugen. LBF-Bericht Nr. FB-106 (1973)
• [6] Wagner C.: Konstruktion und Optimierung einer Flugzeug-Triebwerksaufhängung (Design and optimization of an aircraft engine mount link), Project Work Report, Montanuniversität Leoben, February 2012

Como citar:

Maderbacher, H.; Wagner, C.; Oberwinkler, B.; Gänser, H.-P.; Riedler, M.; "TOPOLOGY AND SHAPE OPTIMIZATION OF A MOUNT LINK CONSIDERING LOCAL MICROSTRUCTURE-DEPENDENT FATIGUE PROPERTIES OBTAINED FROM FORMING SIMULATIONS", p-2220-2230. In: In Proceedings of the 10th World Congress on Computational Mechanics [= Blucher Mechanical Engineering Proceedings, v. 1, n. 1]. São Paulo: Blucher, 2014.
ISSN 23580828, DOI 10.5151/meceng-wccm2012-18748