CN111177861A - Light weight design method of gimbal structure suitable for additive manufacturing forming technology - Google Patents
Light weight design method of gimbal structure suitable for additive manufacturing forming technology Download PDFInfo
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Abstract
A light-weight design method of a gimbal ring structure suitable for an additive manufacturing forming technology is characterized in that structural characteristics, boundary conditions and stress conditions of a gimbal ring product are analyzed, an initial model suitable for gimbal ring topology optimization is established, an optimization design area is determined, a gimbal ring optimal force transmission path and a material distribution initial model are obtained by combining statics optimization analysis, a design criterion considering the gimbal ring optimal topology structure and a good forming quality balance condition is provided, and a brand-new lightweight design model structure based on additive manufacturing is obtained.
Description
Technical Field
The invention belongs to the field of metal manufacturing, and particularly relates to a light-weight design method of a gimbal structure suitable for an additive manufacturing forming technology, in particular to a light-weight design method of a frame bearing component formed by adopting a laser additive manufacturing technology.
Background
The gimbal ring is used as a main bearing part on a gas swing device of the liquid rocket engine, has the functions of transmitting thrust vectors and realizing the swing function, and has successfully applied to the flying launching tasks of a plurality of types of long-standing series rockets. The structural design of a new generation of liquid rocket engine is characterized by large size, integration and light weight, in order to meet the urgent need of reducing weight of the rocket engine, the structural optimization and weight reduction improvement requirements are provided for frame parts such as a gimbal ring, the total height and the mass of the engine are prevented from increasing by reducing the structural mass and adopting reasonable layout, and the influence of state change on the whole engine is reduced.
As shown in fig. 3, the current gimbal component is a frame-like integral web structure, each web is distributed with bearing holes and lightening holes with different sizes, the upper wing plate and the lower wing plate and the web form a [ -shaped surface, the centroid of the profile structure is located at one side close to the web, the line of concentrated force borne by the gimbal is in the middle of the [ -shaped structure, and the concentrated force can generate torque on the centroid of the cross section. When carrying out cross-sectional design and structural optimization to the current gimbal ring and improving, receive current manufacturing process restriction, the improvement scheme still designs based on "empirical formula" thinking, uses structures such as lightening hole, strengthening rib, welding patch more to lighten weight, reinforcing and bear the turn round and the ability of bearing a bend, and measures such as rethread forging, welding, machining are made and are formed, and the manufacturing procedure is many, production cycle is long, and probably there is welding deformation to influence product qualification rate and reliability.
The additive manufacturing technology is one of advanced manufacturing technologies, a three-dimensional manufacturing process of a part is changed into two-dimensional manufacturing by adopting a discrete/accumulation principle, the limitation of the structural complexity of the part is avoided, the characteristic of realizing function-first design is achieved, and the additive manufacturing technology can be perfectly fused with a light-weight technology. The establishment of the light-weight design method of the gimbal structure suitable for the additive manufacturing forming technology can reflect the advantages of additive manufacturing in rapid and short-flow integrated manufacturing, and can realize double improvement of performance and weight reduction through optimized design.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: based on the technical characteristics of additive manufacturing and forming, a light-weight design method for a gimbal structure is provided, the light-weight model design under the optimal force transmission path and material distribution of the gimbal structure is realized, and a brand new method is provided for optimizing the gimbal structure and weight reduction of large-size frames.
The technical scheme adopted by the invention is as follows: a light weight design method of a gimbal structure suitable for an additive manufacturing forming technology comprises the following steps:
(1) establishing a topological optimization initial model of a gimbal and selecting an optimization area;
(2) setting physical property parameters of a material of the gimbal, establishing boundary constraint conditions, and applying a stress working condition on a topological optimization initial model of the gimbal;
(3) carrying out mesh division on the gimbal initial model;
(4) setting an optimization target and additive manufacturing process constraints, and performing statics optimization analysis on the gimbal structure;
(5) analyzing structural rationality of the topology optimization initial model of the gimbal, and reconstructing a gimbal CAD model according to additive manufacturing forming constraints and forming modes;
(6) adding a Lattice structure at the position of a web plate to obtain a gimbal optimization model with a Lattice structure;
(7) and establishing a final model of the gimbal CAD, carrying out simulation analysis on the final model, and verifying whether the final model meets the design requirements.
In the step (1), when the optimized area is selected, the overall contour size of the topology optimization initial model of the gimbal ring is ensured to be the same as that of the existing model, the bearing holes on the periphery and within 20-25 mm in the radial direction are used as non-design optimized areas, and the rest structures are used as optimized areas.
In the step (2), physical parameters of the high-strength stainless steel material for the gimbal are input into lightweight design software, wherein the physical parameters comprise Young modulus, Poisson ratio, density and yield stress; and selecting a zero state of the gimbal for structural optimization, taking two bearing holes in the X or Y direction of the topological optimization initial model of the gimbal as fixed constraint ends, taking the other two symmetrical bearing holes as stress ends, applying corresponding load, wherein the load is the difference between the separation force of the hose and the ground thrust of the engine.
In the step (3), 4-surface units with 10 points are selected for statics optimization analysis, the grid size of the divided units is set to be 1/3-1/6 of the wall thickness of the gimbal ring, simulation analysis is carried out under the boundary conditions and the load working conditions set in the step (2), stress and displacement results under different grid unit size divisions are compared, and grid convergence is judged.
In the step (4), the formable overhanging surface angle and the centrosymmetric constraint of additive manufacturing are set in the optimized area, the formable overhanging surface angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by respectively taking 10-50% weight reduction as an optimization target, the obtained topological optimized structure integrity and stress and displacement calculation data are compared, and a topological structure with a perfect force transmission path and minimal stress deformation is selected.
In the step (5), the determined topology optimization initial model structure of the gimbal ring is analyzed, a three-dimensional gimbal ring model is formed by cladding and fitting in a CAD solid modeling mode, a PolyNURBS polygonal modeling mode and a NURBS curved surface modeling mode, the rod thickness and the transition fillet size are optimized, after the three-dimensional gimbal ring model is completed, the additive manufacturing forming and placing position, the size of an overhanging area and the forming difficulty of the reconstructed gimbal ring model are analyzed, and the chamfer size of a transition part is optimized.
In the step (6), redesigning an optimized weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in a web plate of each side, extracting the area and adding a Lattice structure, wherein the Lattice structure consists of rhombic dodecahedral cells, eight extension ribs extend outwards along the diagonal line of the body, the included angle between each main rib and a projection plane is 41-45 degrees, the length of each cell structure rod is 3-7 mm, the diameter of each cell structure rod is phi 11.0-phi 12.5mm, and the Lattice structures are arranged in a specified direction to form a three-dimensional space array; and performing Boolean combination on the formed three-dimensional space array and the gimbal model to obtain the gimbal model with the lattice structure.
In the step (7), the boundary conditions and the load working conditions set in the step (2) of the final model of the gimbal CAD are subjected to static analysis, stress deformation data of a lightweight structure is calculated and designed, and whether the design requirements are met is checked.
Compared with the prior art, the invention has the advantages that:
(1) the invention provides a light-weight design method of a gimbal structure suitable for an additive manufacturing forming technology, which comprises the steps of establishing an initial model suitable for gimbal topology optimization by analyzing structural characteristics and stress conditions of a gimbal product, determining an optimized design area, obtaining an optimal force transmission path and a material distribution initial model of a gimbal by combining statics optimization, providing a design criterion under the condition of considering both the optimal topology structure and good forming quality balance of the gimbal, and obtaining a brand-new light-weight design model structure based on additive manufacturing.
(2) Compared with the original scheme, the weight of the light-weight design structure for the additive manufacturing of the gimbal ring is reduced by 15%, the stress of the Von Mises is reduced by 10%, the deformation displacement is less than 1mm, and the structure is suitable for the integrated forming of the additive manufacturing without machining.
Drawings
FIG. 1 is a schematic diagram of an initial design model of a gimbal according to an embodiment of the present invention;
fig. 2 is a schematic diagram of a Lattice structure according to an embodiment of the present invention.
Fig. 3 is a structural view of a gimbal.
Detailed Description
A light-weight design method of a gimbal ring structure suitable for an additive manufacturing forming technology comprises the steps of analyzing structural characteristics, boundary conditions and stress conditions of a gimbal ring product, establishing an initial model suitable for gimbal ring topology optimization, determining an optimized design area, combining statics optimization to obtain an optimal force transmission path and a material distribution initial model of the gimbal ring, providing a design criterion considering the optimal topological structure of the gimbal ring and a good forming quality balance condition, and obtaining a brand-new light-weight design model structure based on additive manufacturing. The method comprises the following specific steps:
(1) designing a gimbal topology optimization initial model and an optimization area;
(2) establishing physical property parameters and boundary constraint conditions of the gimbal material and applying stress working conditions;
(3) carrying out mesh division on the gimbal initial model;
(4) setting an optimization target and additive manufacturing process constraints, and performing statics optimization analysis on the gimbal structure;
(5) analyzing the structural rationality of the initial topological optimization model, and reconstructing a gimbal CAD model according to additive manufacturing forming constraints and forming modes;
(6) adding a Lattice structure at the position of the web plate to complete redesigning of the gimbal optimization model;
(7) and carrying out simulation analysis and then verification on the final model of the gimbal CAD.
In the step (1), a large number of lightening holes and reinforcing ribs are distributed on the existing model structure of the gimbal, a force transmission path is shaped, and a space for continuous optimization is not provided, so that an original model needs to be reestablished. The middle part of the gimbal ring is communicated with a gas pipeline, the peripheral bearing holes are required to be assembled and butted with a machining thrust chamber and a thrust chamber, the overall outline size is set to be the same as that of the existing model, the peripheral bearing holes and the radial direction within 20 mm-25 mm are used as non-design optimization areas, and other structures are used as optimization spaces.
In the step (2), physical parameters such as Young modulus, Poisson's ratio, density, yield stress and the like of the high-strength stainless steel material for the gimbal are input into lightweight design software. And selecting a zero state of the gimbal ring for structural optimization, taking two bearing holes in the X or Y direction of the gimbal ring model as fixed constraint ends, taking the other two symmetrical bearing holes as stress ends, and applying corresponding load, wherein the load is the difference between the hose separating force and the ground thrust of the engine.
In the step (3), 4-face units with 10 points are selected for statics optimization analysis, the grid size of the divided units is set to be 1/3-1/6 of the wall thickness size, simulation analysis is carried out under the boundary condition and the load working condition in the step (2), stress and displacement results under different grid unit size divisions are compared, and grid convergence is judged.
In the step (4), the formable overhanging surface angle and the centrosymmetric constraint of additive manufacturing are set in the optimized area, the formable overhanging surface angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by respectively taking 10-50% weight reduction as an optimization target, the obtained topological optimized structure integrity and stress and displacement calculation data are compared, and a topological structure with a perfect force transmission path and small stress deformation is selected.
In the step (5), the determined topology optimization initial model structure is analyzed, a high-quality three-dimensional model with smooth surface and convenient processing is formed by coating and fitting in a CAD solid modeling mode, a PolyNURBS polygonal modeling mode and a NURBS curved surface modeling mode, the sizes of rod thickness, transition fillets and the like are optimized, after the model is completed, the material adding manufacturing forming placing position, the size of an overhanging area and the forming difficulty of the reconstructed gimbal model are analyzed, and the sizes of transition part fillets and the like are optimized.
In the step (6), redesigning an optimized weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in a web plate on each side, extracting the area and adding a Lattice structure, wherein the Lattice structure consists of rhombic dodecahedral cells, eight extension ribs extend outwards along the diagonal line of the body, the included angle between each main rib and a projection plane is 41-45 degrees, the length of each cell structure rod is 3-7 mm, the diameter of each rod is phi 1.0-phi 2.5mm, and the Lattice structures are arranged in a specified direction to form a regular three-dimensional space array with a certain density; and performing Boolean combination on the formed three-dimensional space array and the gimbal model to obtain the gimbal model with the lattice structure.
And (7) carrying out statics analysis on the final model of the gimbal according to the boundary conditions and the load working conditions set in the step (2), calculating stress deformation data of the designed lightweight structure, and checking whether the stress deformation data meet the requirements.
The following is further illustrated with reference to specific examples:
the original machining model of the gimbal ring shown in fig. 1 is designed in a light weight mode, a gas pipeline is communicated with the middle portion of the gimbal ring, peripheral bearing holes need to be assembled and butted with machining and thrust chambers, a frame structure with the overall outline size of 482mm multiplied by 150mm is arranged, the peripheral bearing holes keep unchanged in size, the peripheral bearing holes are used as non-design optimization areas within 20mm in the radial direction of the bearing holes, and other structures are used as optimization spaces.
And inputting physical parameters such as Young modulus, Poisson ratio, density, yield stress and the like of the S-04 high-strength stainless steel material into lightweight design software Optistruct. And selecting a zero state of the gimbal ring for structural optimization, taking two bearing holes in the X direction of the gimbal ring model as fixed constraint ends, taking two other symmetrical bearing holes in the Y direction as stress ends, and applying corresponding load, wherein the load is the difference between the hose separating force and the ground thrust of the engine. Selecting 10-point 4-face unit for grid division, setting the grid size of the division unit to be 6mm, setting the angle of a formable overhanging surface and central symmetry constraint for additive manufacturing on an optimized region, setting the angle of the formable overhanging surface to be 40 degrees, performing structural statics simulation analysis by respectively taking 10%, 20% and 40% of weight reduction as optimization targets, comparing the obtained topological optimization structural integrity and stress and displacement calculation data, and selecting a topological structure with a perfect force transmission path and small stress deformation. Analyzing the determined topology optimization initial model structure, utilizing CAD solid modeling, PolyNURBS polygonal modeling and NURBS curved surface modeling modes to cover and fit a high-quality three-dimensional model with smooth surface and convenient processing, optimizing the same size, analyzing the material increase manufacturing forming placing position, the size of an overhanging area and the forming difficulty of the reconstructed gimbal model after finishing, and optimizing the size of a transition part chamfer angle and the like. Redesigning an optimized weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in a web plate on each side, extracting the area and adding a Lattice structure, wherein the Lattice structure consists of rhombic dodecahedron cells, eight extension ribs extend outwards along the diagonal line of the body, the included angle between each main rib and a projection plane is 41 degrees, the rod length of a single cell structure is 3-7 mm, the rod diameter is 1.5mm, and the Lattice structures are arranged in the specified direction to form a regular three-dimensional array with a certain density, as shown in figure 2; and performing Boolean combination on the formed three-dimensional space array and the gimbal model to obtain the gimbal model with the lattice structure. And (4) carrying out statics analysis on the final model of the gimbal according to the boundary conditions and the load working condition, calculating stress deformation data of the designed lightweight structure, and checking whether the stress deformation data meet the requirements.
Those skilled in the art will appreciate that those matters not described in detail in the present specification are well known in the art.
Claims (8)
1. A light weight design method of a gimbal structure suitable for an additive manufacturing forming technology is characterized by comprising the following steps:
(1) establishing a topological optimization initial model of a gimbal and selecting an optimization area;
(2) setting physical property parameters of a material of the gimbal, establishing boundary constraint conditions, and applying a stress working condition on a topological optimization initial model of the gimbal;
(3) carrying out mesh division on the gimbal initial model;
(4) setting an optimization target and additive manufacturing process constraints, and performing statics optimization analysis on the gimbal structure;
(5) analyzing structural rationality of the topology optimization initial model of the gimbal, and reconstructing a gimbal CAD model according to additive manufacturing forming constraints and forming modes;
(6) adding a Lattice structure at the position of a web plate to obtain a gimbal optimization model with a Lattice structure;
(7) and establishing a final model of the gimbal CAD, carrying out simulation analysis on the final model, and verifying whether the final model meets the design requirements.
2. The method of claim 1, wherein the method comprises: in the step (1), when the optimized area is selected, the overall contour size of the topology optimization initial model of the gimbal ring is ensured to be the same as that of the existing model, the bearing holes on the periphery and within 20-25 mm in the radial direction are used as non-design optimized areas, and the rest structures are used as optimized areas.
3. The method of claim 1 or 2, wherein the method comprises: in the step (2), physical parameters of the high-strength stainless steel material for the gimbal are input into lightweight design software, wherein the physical parameters comprise Young modulus, Poisson ratio, density and yield stress; and selecting a zero state of the gimbal for structural optimization, taking two bearing holes in the X or Y direction of the topological optimization initial model of the gimbal as fixed constraint ends, taking the other two symmetrical bearing holes as stress ends, applying corresponding load, wherein the load is the difference between the separation force of the hose and the ground thrust of the engine.
4. The method of claim 3, wherein the method comprises: in the step (3), 4-surface units with 10 points are selected for statics optimization analysis, the grid size of the divided units is set to be 1/3-1/6 of the wall thickness of the gimbal ring, simulation analysis is carried out under the boundary conditions and the load working conditions set in the step (2), stress and displacement results under different grid unit size divisions are compared, and grid convergence is judged.
5. The method of claim 4, wherein the method comprises: in the step (4), the formable overhanging surface angle and the centrosymmetric constraint of additive manufacturing are set in the optimized area, the formable overhanging surface angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by respectively taking 10-50% weight reduction as an optimization target, the obtained topological optimized structure integrity and stress and displacement calculation data are compared, and a topological structure with a perfect force transmission path and minimal stress deformation is selected.
6. The method of claim 5, wherein the method comprises: in the step (5), the determined topology optimization initial model structure of the gimbal ring is analyzed, a three-dimensional gimbal ring model is formed by cladding and fitting in a CAD solid modeling mode, a PolyNURBS polygonal modeling mode and a NURBS curved surface modeling mode, the rod thickness and the transition fillet size are optimized, after the three-dimensional gimbal ring model is completed, the additive manufacturing forming and placing position, the size of an overhanging area and the forming difficulty of the reconstructed gimbal ring model are analyzed, and the chamfer size of a transition part is optimized.
7. The method of claim 6, wherein the method comprises: in the step (6), redesigning an optimized weight reduction area for the gimbal ring, dividing a continuous area with a VonMises stress value smaller than 500MPa in each side of a web plate, extracting the area and adding a Lattice structure, wherein the Lattice structure consists of rhombic dodecahedron cells, eight extension ribs extend outwards along the diagonal line of the body, the included angle between each main body rib and a projection plane is 41-45 degrees, the length of each single cell structure rod is 3-7 mm, the diameter of each rod is phi 11.0-phi 12.5mm, and the Lattice structures are arranged in a specified direction to form a three-dimensional space array; and performing Boolean combination on the formed three-dimensional space array and the gimbal model to obtain the gimbal model with the lattice structure.
8. The method of claim 7, wherein the method comprises: in the step (7), the boundary conditions and the load working conditions set in the step (2) of the final model of the gimbal CAD are subjected to static analysis, stress deformation data of a lightweight structure is calculated and designed, and whether the design requirements are met is checked.
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| CN114178553A (en) * | 2021-11-30 | 2022-03-15 | 西安交通大学 | Method and system for determining optimal forming direction of workpiece in additive manufacturing process |
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