Streamlined aircraft part
The additive manufacturing process for aircraft parts with a profiled shape addresses the challenges of cost and mass by optimizing material distribution and simplifying production, resulting in lighter and more efficiently manufactured components.
Patent Information
- Application Number
- FR2021003199
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2021-03-29
- Publication Date
- 2025-05-02
- Estimated Expiration
- 2041-03-29
AI Technical Summary
The manufacturing of aircraft parts is costly and heavy, posing challenges in terms of both mass and cost optimization.
A manufacturing process using additive manufacturing to create aircraft parts with a profiled shape, where each layer is parallel to the profile, allowing for a part that is geometrically superimposable to a two-dimensional profile, thereby optimizing material distribution and simplifying production.
This process results in parts that meet mechanical requirements while reducing mass and manufacturing complexity, achieving a mass gain of approximately 23% compared to traditional methods.
Smart Images
Figure 00000010_0000 
Figure 00000011_0000 
Figure 00000012_0000
Abstract
Description
Title of the invention: Method for manufacturing an aircraft part of profiled shape FIELD OF THE INVENTION
[0001] The invention relates to methods of manufacturing aircraft parts. STATE OF THE ART
[0002] Aircraft landing gear is composed of structural parts (box, strut, shock absorber, wheel) taking the weight of the aircraft during taxiing, takeoff and landing, but also of various equipment (electrical systems, hydraulic systems, headlights, sensors, cables etc.). This equipment is often fixed to the structural parts by means of parts commonly called bracket or connecting part. The processes for obtaining these parts are diverse: machining, foundry, mechanically welded sheets, etc.
[0003] The manufacturing cost of these parts and their mass on board the aircraft are often substantial. It is therefore interesting to seek to improve at least one of these two aspects.
[0004] An aim of the invention is to improve aircraft parts in terms of manufacturing cost and / or mass. Statement of the invention
[0005] For this purpose, a manufacturing method is provided,
[0006] method in which an aircraft part is produced having a larger part geometrically superimposable on a profiled shape following a two-dimensional profile which is non-symmetrical with respect to a plane or with respect to a point,
[0007] the profile having at least one closed cell defining at least one internal veil of the part,
[0008] process in which the part is produced by additive manufacturing by arranging layers of material successively on top of each other,
[0009] each layer being parallel to the profile.
[0010] 3D printing processes offer new design possibilities in terms of achievable shapes. These possibilities make it possible to optimize the design / manufacturing couple in order to have a part meeting the mechanical expectations and the simplest possible manufacturing in order to limit costs. A part is manufactured which occupies at least part of each of the walls defined by the profile while leaving completely free the spaces left empty by this profile. The invention makes it possible to improve the distribution of the material of the part according to the interfaces and the loads, for a lower mass. Indeed, whatever the shape that a part may have in the prior art, it is replaced thanks to the invention by a part whose profile constitutes a two-dimensional sketch. As this part is produced by additive manufacturing by placing successive layers of material on top of each other, each layer being parallel to the profile, the part is in a way extruded following the additive manufacturing direction, which makes this manufacturing particularly simple to carry out. The part therefore makes it possible to satisfy the mechanical criteria as well as the manufacturing constraints. The interface functions can be kept identical between the part of the invention and its version of the prior art, if it exists. Its structural strength makes it possible, if necessary, to satisfy the same dimensioning requirements. The invention also makes it possible to improve the distribution of the material in a given volume without impacting the environment close to the part.This is particularly interesting, if it is a landing gear part, during the landing gear extension and retraction phases.
[0011] The material of the part is not limiting for the invention. The part can be made of various materials, in particular metal or metal alloy, for example different shades of aluminum.
[0012] By "largest part of the room" is preferably meant the largest part of the volume of the room.
[0013] It can be provided that at least 60% of the part, in particular at least 70%, is geometrically superimposable on the profiled shape.
[0014] It can also be provided that at most 97% of the part is geometrically superimposable on the profiled shape.
[0015] In one embodiment, the part is configured such that the profiled shape is entirely contained within the part.
[0016] A larger portion of the part then has exactly the same shape as if it had been made by extrusion.
[0017] However, this situation is not obligatory within the scope of the invention. It is thus possible in another embodiment to provide that a larger part of the part is geometrically superimposable on a profiled shape without the profiled shape being entirely included in the part. This is for example the case when a large part of the part is not profiled according to this profile since this profile has different interruptions in numerous sections of the part perpendicular to the direction 6, these interruptions being different from one section to another.
[0018] According to the invention, an aircraft part is also provided,
[0019] a larger part of the part being geometrically superimposable on a profiled shape following a two-dimensional profile which is non-symmetrical with respect to a plane or with respect to a point,
[0020] the profile having at least one closed cell defining at least one internal veil of the room.
[0021] The part may also have at least one of the following characteristics:
[0022] - the part is non-structural;
[0023] - it forms a support part for at least one piece of equipment;
[0024] - it comprises at least one pipeline;
[0025] - it has circular orifices for receiving fixing members;
[0026] - it comprises at least one openwork wall;
[0027] - the cell or at least one of the cells has a non-symmetrical shape by in relation to a plane or in relation to a point;
[0028] - the part forms a landing gear part; and
[0029] - it was produced by additive manufacturing.
[0030] According to the invention, a landing gear is also provided comprising at least one part according to the invention. DESCRIPTION OF FIGURES
[0031] We will now present embodiments of the invention by way of non-limiting examples in support of the drawings in which:
[0032] [Fig. 1] [Fig. 1] is a perspective view of part of a landing gear aircraft according to the invention;
[0033] [Fig.2]
[0034] [Fig.3] Figures 2 and 3 are perspective and front views of a first part landing gear connection of [Fig.l], forming a first embodiment of the invention;
[0035] [Fig.4]
[0036] [Fig.5] Figures 4 and 5 are similar views showing a second part of landing gear connection of [Fig.l], forming a second embodiment of the invention; and
[0037] [Fig.6]
[0038] [Fig.7]
[0039] [Fig. 8]
[0040] [Fig.9] Figures 6 to 9 are similar views showing a third part of landing gear connection of [Fig.l], forming a third embodiment of the invention.
[0041] We will present three parts 100, 200 and 300 which constitute embodiments of the invention and which in this case form part of the aircraft landing gear 2 illustrated in [Fig.l]. These three parts have a reduced mass and are easy to manufacture by additive manufacturing. First embodiment
[0042] We will present a first embodiment of the part 100 according to the invention with reference to figures 2 and 3.
[0043] This is a non-structural part which constitutes a connecting and support part for at least one piece of equipment on the train.
[0044] A larger part of the part has a general shape profiled in a rectilinear direction 6, perpendicular to the profile. The profile 4 is in two dimensions, is notably visible in [Fig. 3] and extends in the plane of the latter. It is non-symmetrical with respect to a plane or with respect to a point. This means that there is no plane or point with respect to which this profile is symmetrical. The profile defines the greater part of the outline of the part. The profile here has a general shape of a bishop's miter, although of asymmetrical shape.
[0045] It has closed cells 8, in this case five in number. Each cell 8 here also has a non-symmetrical shape with respect to a plane or with respect to a point.
[0046] The part comprises external walls 10 and internal webs 12, in this case four in number. The walls and the webs are formed in whole or in part by the cells 8 of the profile.
[0047] The part 100 has circular orifices 114, 116 for receiving fixing members such as screws. The orifices 114 have axes parallel to each other and to the plane of the profile, and therefore perpendicular to the direction 6. They are located in a first end zone of the part. The orifices 116 also have axes parallel to each other in this case, but these axes are parallel to the direction 6. They are located in a second end zone of the part opposite the first.
[0048] The part having a generally profiled shape, it is here particularly simple to note that a larger part of the part is geometrically superimposable on a profiled shape following a non-symmetrical profile with respect to a plane or with respect to a point. Indeed, this profiled shape on which it is superimposable is entirely part of the part itself. And it is clearly verified that the profile has closed cells 8 defining internal sails 12 of the part. In this case, it is 95% of the part which is superimposable on the profiled shape.
[0049] This part 100 can advantageously be produced by an additive manufacturing process. In this process, layers of material are arranged successively on top of each other in a manner known per se. Each layer is parallel to the profile so that [Fig. 3] also represents the general shape of one or more of the layers. Given the general profiled shape of the part, the arrangement of the successive layers is in some way equivalent to an extrusion of the part along the direction 6, as if the part were emerging from a die whose shape would be that of the profile. The "extradited" pattern allows the construction of the part without support and therefore simplifies manufacturing.
[0050] The part is for example made of aluminum.
[0051] The optimization of the shape of the part and additive manufacturing make it possible in this case to achieve a mass saving of approximately 23% compared to a version of the part prior to the invention.
[0052] When designing the part of the invention, it is important to ensure that the areas where the material is necessary are identified to ensure resistance to integration constraints (interfaces, geometry, available external volume) and loading constraints (mechanical resistance to forces and stiffness) while reducing mass. Here, the part thus has a two-dimensional pattern, configured to resist the loads applied to the part. Second embodiment
[0053] The part 200 is illustrated in Figures 4 and 5 and forms a second embodiment of the invention. The characteristics of this embodiment common to the first embodiment will not be repeated. We therefore only describe the differences between the two.
[0054] This time, the part, the profile of which is illustrated in [Fig.5], has a general “U” shape in the lower part of the latter, the “U” being oriented towards the right. The profile has a roughly triangular shape in the upper part.
[0055] The part comprises a lower external wall 10, a left external wall 10, an internal web 12 and a right external wall 10. The left wall 10 and the internal web 12 are here perforated, in this case by networks of orifices 22, here oblong. This makes it possible to improve the mass saving without impacting the manufacturability or the mechanical strength of the part. Indeed, perforating the walls or the webs in the areas not mechanically loaded allows an additional mass saving without weakening the part.
[0056] The part has two upper arms 11 on the left side extending in projection towards the left, facing each other and parallel to each other.
[0057] The part comprises two hoops 23 each having two ends connected to the internal veil 12. The two hoops are identical and extend opposite one another, parallel to one another. They are connected in the upper part to the upper arm 11 of which they form the base.
[0058] The part comprises two coaxial circular orifices 213 located opposite each other in the upper part of the part. The common axis of these orifices is parallel to the direction 6. Each of the arms 11 has two circular fixing orifices 214, coaxial respectively with those of the other arm. The four orifices 214 are identical to each other in this case.
[0059] The part also has on the right external wall 10 two fixing notches 20 opening respectively into opposite front and rear edges of the lower part. of the part, the notches being open in the direction 6. The part further comprises on the same wall 10 a third notch 27 open in the direction of the bottom of the part.
[0060] The orifices 213, 214 and the notches 20, 27 can be used to receive members for fixing to equipment and / or for positioning the part 200 within the landing gear.
[0061] As stated, a profile view of the part 200 is illustrated in [Fig. 5]. However, a large portion of the part is not profiled according to this profile since this profile has different interruptions in numerous sections of the part perpendicular to the direction 6, these interruptions being different from one section to another.
[0062] On the other hand, we can consider a geometric volume profiled along direction 6 by means of the profile of [Fig.5]. This corresponds to producing the part without the aforementioned interruptions in the different sections. We then observe that a larger part of the part 200 is geometrically superimposable on the profiled shape constituted by this volume. In other words, the part 200 occupies the walls defined by this volume without occupying the spaces left empty by this volume. We also observe that the profile is non-symmetrical with respect to a plane or with respect to a point, and that it has two closed cells, respectively high and low 8, defining between them the internal veil 12 of the part. The largest part mentioned above includes all the walls 10, the veil 12, the arms 11 and the arches 23. In this case, it is 85% of the part which is superimposable on the profiled shape.
[0063] Again, the profile forms a two-dimensional pattern that allows easy production in metal additive manufacturing. The profile is generated in order to meet the mechanical criteria for dimensioning the part to external stresses. Third embodiment
[0064] A third embodiment of the part according to the invention is illustrated in Figures 6 to 9.
[0065] This time, the part forms a hydraulic transfer block and includes pipes 24.
[0066] It comprises a profiled main body 26 which has an arrangement close to that of the part of the first embodiment. There are internal sails 12, here ten in number, and cells 8 defining these, also ten in number in this case. There are also the orifices 314, 316.
[0067] The body 26 also carries pipes 24, in this case eight in number. Some are open in the direction 6 at their mouth and others are open at this location in another direction. Most of these pipes have a non-rectilinear shape.
[0068] Just as in the first embodiment, the body 26 having a generally profiled shape, it is particularly simple to note that a larger part of the part 300 formed by this body 26 is geometrically superimposable on a profiled shape following a non-symmetrical profile with respect to a plane or with respect to a point. Indeed, this profiled shape on which it is superimposable is entirely part of the body 26 itself. And it is clearly verified that the profile has closed cells 8 defining internal sails 12 of the part. In this case, it is 75% of the part which is superimposable on the profiled shape.
[0069] Here the profile is dimensioned to satisfy mechanical criteria but also to serve as support for the pipes 24 and to optimize the construction of the part in additive manufacturing. Indeed, here the orientation of the direction 6 chosen for the manufacture of the part by means of the two-dimensional pattern has been selected in order to make it possible to manufacture the internal areas of the pipes without support. The areas 19 indicated on [Fig.9] by an ellipse are the areas of the pattern or profile adapted to serve as support for the pipe areas of the part.
[0070] Numerous modifications may be made to the invention without departing from its scope.
Claims
Claims
1. Manufacturing method, method in which an aircraft part (100; 200; 300) is produced having a larger part geometrically superimposable on a profiled shape following a non-symmetric two-dimensional profile with respect to a plane or with respect to a point, the profile having at least one closed cell (8) defining at least one internal web (12) of the part, method in which the part is produced by additive manufacturing by arranging layers of material successively on top of each other, each layer being parallel to the profile.
2. Method according to the preceding claim, in which at least 60% of the part, in particular at least 70%, is geometrically superimposable on the profiled shape.
3. Method according to at least one of the preceding claims, wherein at most 97% of the part is geometrically superimposable on the profiled shape.
4. Method according to at least one of the preceding claims, wherein the profiled shape is entirely included in the part.
5. Aircraft part (100; 200; 300), manufactured by means of a method according to at least one of the preceding claims.
6. Part (100; 200; 300) according to the preceding claim, in which the part is non-structural.
7. Part (100; 200; 300) according to at least one of claims 5 to 6, forming a support part for at least one piece of equipment.
8. Part (300) according to at least one of claims 5 to 7, comprising at least one pipe (24).
9. Part (100; 200; 300) according to at least one of claims 5 to 8, having circular orifices (114, 116; 214, 216; 314, 316) for receiving fixing members.
10. Part (100; 200; 300) according to at least one of claims 5 to 9, comprising at least one perforated wall (10, 12).
11. Part (100; 200; 300) according to at least one of claims 5 to 10 in which the cell or at least one of the cells (8) has a non-symmetrical shape relative to a plane or relative to a point.
12. Part (100; 200; 300) according to at least one of claims 5 to 11, forming a landing gear part (2).
13.
14. Part (100; 200; 300) according to at least one of claims 5 to 12, produced by additive manufacturing. Landing gear (2) comprising at least one part (100; 200; 300) according to at least one of claims 5 to 13.