A method for optimizing the structure of a complex runner part based on additive manufacturing

Abstract

The application discloses a kind of based on the optimization method of complex runner class part structure of additive manufacturing, comprising the following steps: feature analysis and identification are carried out to original fuel regulator device structure;Based on the evaluation of original fuel regulator device structure to additive manufacturing process and process applicability analysis;Under the constraint condition of laser selective melting process SLM, main runner structure optimization design research is carried out;The main runner structure form and the main runner space structure layout are optimized iteratively designed in combination with fluid simulation analysis, and the external structure feature design is carried out based on the optimization of main runner structure;The performance of optimization model is verified by comparing the parameters of original fuel regulator device with the optimized fuel regulator device, and the above-mentioned optimization method based on the complex runner class part structure of additive manufacturing is used, which forms design experience and method accumulation for the lightweight design of complex runner class parts, and lays a foundation for the development of additive manufacturing components.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of complex flow channels, and in particular to a complex flow channel part structure optimization method based on additive manufacturing. BACKGROUND

[0002] The afterburner fuel control device is planned to be equipped with a new engine. In order to further improve the performance of the product and meet the technical requirements of the engine, the design, trial production and verification of some accessories need to be improved in order to narrow the gap between the engine and the fourth generation engine and the carrier aircraft in terms of control system indicators.

[0003] The previous new engine control device is based on the machining-casting process, and is completed from the aspects of system technical indicators and reliability, maintainability, safety, supportability, testability and environmental adaptability, and combined with the research experience of Honglin Company in similar products. The new engine afterburner fuel control device engineering design work is completed. When the first delivery is made, the product principle architecture is reasonable, and the function performance data all meet the requirements of the host machine, but the weight of the product exceeds the expected design indicators, so the weight reduction research of the new engine afterburner fuel control device is needed. The new engine afterburner fuel control device is mainly composed of self-made components and purchased parts. Considering that the weight of the self-made components accounts for more than 50% of the total weight, the new engine shell is taken as the object of optimization and weight reduction in this project. Requirements: After the shell is lightened, it still needs to meet the carrier of other components and oil circuits, ensure that the product strength is qualified, the working principle oil circuit connection is correct, and the flow channel design is reasonable.

[0004] The selective laser melting (SLM) process is a precision additive manufacturing technology that has developed very rapidly in the past two decades. Through selective layer-by-layer melting of metal powder, high dimensional accuracy, high performance and high density near-net shaped metal parts can be directly obtained. Its layer-by-layer manufacturing and stacking technology characteristics have broken through the limitations of complex part configuration on manufacturing in traditional processes, greatly shortening the design and manufacturing cycle. Because the laser spot diameter used in selective laser melting is small and the forming precision is high, it is particularly suitable for the integrated forming of complex structure parts, realizes the topological optimization and lattice optimization of parts, and can greatly reduce the weight of the product while meeting the functional requirements of the product.

[0005] Given that SLM technology has been fully validated in other similar engine products with good weight reduction results, this weight reduction design scheme, while ensuring that all components can still be assembled and the engine interfaces remain unchanged, fine-tunes the main flow channel according to the self-forming conditions of additive manufacturing, optimizes the conformal design of other flow channels, redesigns the shell according to the characteristics of additive forming, and achieves shell weight reduction through additive manufacturing design technology, forming process, and additive post-processing technology. Regarding materials, the original fuel control device shell material was ZL105A aluminum alloy. Considering the maturity of SLM-printed aluminum alloys, this project selected the most mature AlSi10Mg alloy. In terms of structural design, based on the previous design and screening of the crystal structure, analysis of microstructure defects and mechanical properties, this project selected a topology-optimized octahedral structure with a unit cell size of 3mm and 85% porosity as the basic unit for shell lattice weight reduction. Summary of the Invention

[0006] The purpose of this invention is to provide an optimization method for complex flow channel parts based on additive manufacturing, thereby accumulating design experience and methods for lightweight design of complex flow channel parts and laying the foundation for the development of additive manufacturing components.

[0007] This invention provides an optimization method for complex flow channel part structures based on additive manufacturing, including the following steps: S1, performing feature analysis and identification on the original fuel regulator device structure to obtain feature identification results;

[0008] S2. Based on the additive manufacturing process and process applicability analysis, evaluate the structure of the original fuel regulator device;

[0009] S3. Extract the flow channel structure features of the original fuel regulator device structure obtained in step S1. The flow channel includes the main flow channel and the inner flow channel. Under the constraint of laser selective melting process (SLM), carry out the main flow channel structure optimization design research.

[0010] S4. Combine fluid simulation analysis to optimize and iterate the design of the main channel structure and the main channel spatial structure layout, determine the optimization scheme of the main channel structure, and then rearrange the structural features of the inner channel.

[0011] If the adjustment of the SLM constraint of the laser selective melting process is satisfied, proceed to step S5; otherwise, return to step S3.

[0012] S5. Based on the optimization of the main road structure, carry out the design of external structural features;

[0013] S6, verify the performance of the optimization model by comparing the parameters of the optimized fuel regulator device with the original fuel regulator device, if step S6 meets the weight loss benefit of the technical requirements, output the optimized fuel regulator device, if step S6 does not meet the weight loss benefit of the technical requirements, return to step S5.

[0014] Preferably, in step S1, the characteristics of the original fuel regulator device structure include flow channel structure characteristics, mounting structure characteristics and assembly structure characteristics.

[0015] Preferably, in step S2, the analysis of the additive manufacturing process and process applicability includes the spatial placement direction of part printing.

[0016] Preferably, in step S3, the constraint conditions of the selective laser melting process SLM include the basic constraint of the overhanging angle, the overhanging constraint of the internal cavity feature and the powder cleaning constraint of the internal cavity.

[0017] Preferably, in step S5, the external structure feature design includes mounting structure features and assembly structure features, the mounting structure features include valve core structure and pipe joint, and the assembly structure features include fuel control device implanted point lattice structure, and the performance and structural strength of the fuel regulator device structure are analyzed in combination with static strength and vibration simulation analysis.

[0018] Preferably, in step S6, the weight loss benefit is to design the external envelope structure of the fuel regulator device structure based on the flow channel structure optimization scheme.

[0019] Preferably, in step S6, the checking includes static strength checking and vibration checking.

[0020] Therefore, the application adopts the above-mentioned optimization method for complex flow channel type parts based on additive manufacturing, which forms design experience and method accumulation for lightweight design of complex flow channel type parts, and lays a foundation for the development of additive manufacturing components.

[0021] The technical solutions of the application will be further described in detail below with reference to the drawings and examples. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 The overall flow chart of the optimization method for complex flow channel type parts based on additive manufacturing of the application. DETAILED DESCRIPTION

[0023] The technical solutions of the application will be further described in detail below with reference to the drawings and examples.

[0024] Unless otherwise defined, the technical terms or scientific terms used in the application shall have the usual meaning understood by those skilled in the art.

[0025] Embodiment one

[0026] As Figure 1 shown, the method for optimizing the structure of a complex flow channel type part based on additive manufacturing, comprising the following steps:

[0027] S1, feature analysis and identification of the original fuel regulator device structure, and obtain the feature identification result;

[0028] The features of the original fuel regulator device structure include flow channel structure features, mounting structure features and assembly structure features.

[0029] S2, based on the additive manufacturing process and process suitability analysis, the original fuel regulator device structure is evaluated;

[0030] In step S2, the additive manufacturing process and process suitability analysis includes the spatial placement direction of the part printing.

[0031] S3, extract the flow channel structure features of the original fuel regulator device structure obtained in step S1, the flow channel includes the main flow channel and the inner flow channel, and carry out the main flow channel structure optimization design research under the constraint condition of laser selective melting process SLM;

[0032] In step S3, the constraint conditions of laser selective melting process SLM include the basic constraint of overhanging angle, the overhanging constraint of inner cavity type feature and the powder cleaning constraint of inner cavity.

[0033] The basic constraint of overhanging angle: because in the process of laser selective melting process SLM technology, the metal powder has the tendency of collapse under the action of gravity, and the part will also be continuously interfered by the reciprocating motion of the scraper during processing. Therefore, in the process of part processing, the part with too low overhanging angle cannot be directly formed, and the prerequisite for the natural printing formation and good forming quality of the related features is to ensure that the angle A (overhanging angle) between the related features and the horizontal plane (substrate) is ≥45° when the part is placed in the corresponding direction, otherwise support structure needs to be added. If the overhanging angle is too low, the forming quality will be significantly affected, and if the overhanging angle is located in the internal area of the part, such as the internal area of the deep cavity or the area with relatively tortuous and narrow space environment, the added support may not be effectively removed, resulting in that the part cannot meet the use requirements. In order to solve this problem, the part placement adjustment or internal detail feature adjustment can be used to realize the forming of the key features of the part.

[0034] Internal cavity features with overhang constraints: Since additive manufacturing parts are mostly irregularly shaped structures, they often contain various flow channels and cavities. These flow channels and cavities have specific shape and precision requirements. Therefore, product designers need to consider the form and arrangement of cavities and flow channels in corresponding locations to avoid large overhangs within the internal cavities or flow channels. If there are large overhangs in the flow channel structure, adjusting the flow channel cross-section can be considered.

[0035] Powder removal constraints for internal cavities: Since the raw material for metal additive manufacturing is powder, unmelted powder will deposit in the internal cavity of the part after printing, and the residual powder needs to be removed subsequently. Therefore, the structure of the part cannot have completely closed cavities during printing. If the actual part has closed cavities, powder leakage holes can be pre-set on the part, and after the printing and powder removal processes are completed, they can be sealed by mechanical means or welding.

[0036] S4. Combine fluid simulation analysis to optimize and iterate the design of the main channel structure and the main channel spatial structure layout, determine the optimization scheme of the main channel structure, and then rearrange the structural features of the inner channel.

[0037] If the adjustment of the SLM constraint of the laser selective melting process is satisfied, proceed to step S5; otherwise, return to step S3.

[0038] S5. Based on the optimization of the main road structure, carry out the design of external structural features;

[0039] In step S5, the external structural feature design includes installation structural features and assembly structural features. The installation structural features include valve core structure and pipe joints, and the assembly structural features include fuel control device with embedded lattice structure. The performance and structural strength of the fuel regulator device structure are analyzed by combining static strength and vibration simulation analysis.

[0040] Taking into account the process characteristics of additive manufacturing, the working load conditions of the parts, and the external assembly features, the external shell structure of the fuel control device is optimized and a lattice structure is embedded. Combined with static strength and vibration simulation analysis, the performance and structural strength of the fuel control device structure are optimized and iteratively designed, and finally the optimal fuel regulator device structure is determined.

[0041] S6. The performance of the optimization model is verified by comparing the calibration parameters of the optimized fuel regulator device with those of the original fuel regulator device. If step S6 meets the weight reduction benefits required by the technical requirements, the optimized fuel regulator device is output. If step S6 does not meet the weight reduction benefits required by the technical requirements, the process returns to step S5.

[0042] In step S6, the weight-reduction benefit is used to design the external envelope structure of the fuel regulator device based on the flow channel structure optimization scheme.

[0043] In step S6, the checking calculation includes static strength checking and vibration checking.

[0044] Therefore, the application adopts the above-mentioned optimization method of complex flow channel part structure based on additive manufacturing to form design experience and method accumulation for lightweight design of complex flow channel parts and lay a foundation for development of additive manufacturing components.

[0045] Finally, it should be noted that: the above examples are only used to illustrate the technical solutions of the present application rather than limit them, although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that: its still can modify or equivalent replacement of the technical solutions of the present application, and these modifications or equivalent replacement also can not make the modified technical solutions deviate from the spirit and scope of the technical solutions of the present application.

Claims

1. A method for optimization of complex runner-like part structures based on additive manufacturing, characterized in that, Comprising the following steps: S1, fully analyzing and identifying the structure of the fuel regulator device; S2, based on the experience accumulation and process applicability constraint analysis of the additive manufacturing process, evaluating the printing process applicability of the fuel regulator device structure; S3, extracting the flow channel features of the original fuel regulator device structure, and carrying out main flow channel structure optimization design research under the constraint conditions of the SLM process; In step S3, the SLM process constraint conditions include the basic constraint problem of overhang angle, the overhang problem of internal cavity features, and the powder cleaning problem of internal cavity; S4, combining fluid simulation analysis to optimize and iteratively design the structure form and spatial structure layout of the flow channel, determine the optimal scheme of the main flow channel structure, and then re-arrange and design other internal flow channel features; If the adjustment meets the SLM process constraints, proceed to step S5, if the adjustment does not meet the SLM process constraints, return to step S3; In step S4, in addition to meeting the SLM process constraint conditions, the internal flow channel design also considers reducing the flow channel length and adopting the design of common wall thickness; S5, on the basis of optimizing the flow channel structure, carry out external structural feature design research; In step S5, considering the process characteristics of additive manufacturing, the working load conditions of the part and the external assembly features, optimize the external shell structure of the fuel control device and implant the lattice lattice structure, and combine static strength and vibration simulation analysis to optimize and iteratively design the performance, structural strength and other performances of the fuel control device structure, and finally determine the optimal scheme of the fuel regulator device structure; S6, checking calculation verifies the performance of the optimized model by comparing the parameters of the optimized model and the original model of the fuel regulator control device, if step S6 meets the weight reduction benefit of the technical requirements, determine the scheme, if step S6 does not meet the weight reduction benefit of the technical requirements, return to step S5; In step S6, the weight reduction benefit that meets the requirements is to design the external envelope structure of the fuel control device structure based on the optimal scheme of the flow channel structure; In step S6, the checking calculation includes static strength checking and vibration checking.

2. The method for optimization of complex runner type part structure based on additive manufacturing as claimed in claim 1 wherein, In step S1, the fuel regulator device structure includes flow channel structure, mounting structure and assembly structure.

3. The method for optimization of complex runner type part structure based on additive manufacturing as claimed in claim 1 wherein, In step S2, considering the printing process characteristics of the part and the process requirements of traditional machining, determine the part printing and the spatial placement direction of the part printing.

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