Additive-Manufactured Torque Bar for Stiffness and Vibration Damping
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Solution Overview
Problem
Conventional manufacturing techniques for torque bars in aircraft wheel and brake assemblies limit their geometric configurations, leading to inadequate resistance against deflection and vibration.
Innovation Solution
The use of additive manufacturing processes to design and produce torque bars with optimized geometries, including varying cross-sectional profiles and voids, enhances stiffness and vibration damping characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional subtractive manufacturing techniques are used to manufacture torque bars, then manufacturing simplicity is maintained, but geometric flexibility and performance characteristics (stiffness and vibration resistance) are limited
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional subtractive manufacturing to additive manufacturing processes. This fundamental manufacturing parameter change enables the creation of complex geometries including varying cross-sectional profiles, hollow sections, and optimized structural configurations that cannot be achieved through traditional methods. The additive manufacturing approach resolves the contradiction by prioritizing geometric flexibility while accepting increased manufacturing complexity as a necessary trade-off for superior performance.
2Reliability
If torque bars are designed with optimized geometries to resist deflection and vibration, then dynamic stability is improved, but manufacturing difficulty increases due to geometric complexity
Solution Approach 1:
The patent applies segmentation by dividing the torque bar into distinct structural zones with different cross-sectional profiles along its length. Each segment is optimized for specific functional requirements: certain sections have enhanced stiffness to resist deflection, while other areas incorporate hollow sections or reduced material density to dampen vibration. This segmented approach allows complex geometries to be systematically designed and manufactured using additive processes, resolving the contradiction between dynamic stability and manufacturing difficulty.
3Strength
If torque bars use uniform cross-sectional profiles for simplicity of manufacture, then manufacturing ease is maintained, but stiffness and structural performance are compromised
Solution Approach 1:
The patent applies local quality by varying the cross-sectional profile at different locations along the torque bar rather than using a uniform section throughout. Specific regions are designed with enhanced thickness, hollow sections, or optimized geometries to provide localized stiffness where structural demands are highest. This approach resolves the contradiction by concentrating geometric complexity only where needed for performance, rather than uniformly across the entire component.
Data Source
AI summary
A torque bar manufactured by an additive manufacturing process is provided. The torque bar may include a torque bar body made of more than one metallic material. The torque bar may also include a geometry that comprises one or more voids and one or more webs, as well as a varied geometry in the direction of a longitudinal axis. The torque bars can exhibit characteristics, such as vibration damping, tuned stiffness, and tuned bending resistance in order to enhance dynamic stability.