CN111177861B - Constant-normal ring structure lightweight design method suitable for additive manufacturing forming technology - Google Patents
Constant-normal ring structure lightweight design method suitable for additive manufacturing forming technology Download PDFInfo
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Abstract
A design method for the light weight of the gimbal structure suitable for the additive manufacturing shaping technology is characterized in that the structural characteristics, boundary conditions and stress conditions of the gimbal product are analyzed, an initial model suitable for the gimbal topological optimization is established, an optimal design area is determined, the optimal force transmission path of the gimbal and the initial model of material distribution are obtained by combining with statics optimization analysis, the design criterion considering the optimal topological structure of the gimbal and the good shaping quality balance condition is provided, and a brand-new light weight design model structure based on the additive manufacturing is obtained.
Description
Technical Field
The invention belongs to the field of metal manufacturing, and particularly relates to a design method for lightening a gimbal structure, which is suitable for an additive manufacturing forming technology, in particular to a design method for lightening a frame type bearing member formed by adopting a laser additive manufacturing technology.
Background
The gimbal ring is used as a main bearing piece on a gas swinging device of a liquid rocket engine, and has the functions of transmitting thrust vectors and realizing swinging, and is successfully applied to the flight launching tasks of a plurality of types of long-sign series rockets. The new generation liquid rocket engine structural design is characterized by large size, integration and light weight, in order to meet urgent requirements of rocket engine weight reduction, requirements of structural optimization and weight reduction improvement are provided for frame parts such as gimbal and the like, and by reducing structural quality, the reasonable layout is adopted to avoid the total increase and the mass increase of the engine, and the influence of state change on the whole engine is reduced.
As shown in fig. 3, the conventional gimbal ring part is of a frame-like integral web structure, each web is provided with bearing holes and weight-reducing holes with different sizes, an upper wing plate and a lower wing plate form a [ -shaped surface with the web, the centroid of the profile structure is positioned at one side close to the web, the acting line of concentrated force born by the gimbal ring is in the middle of the [ -shaped structure, and the concentrated force can generate torque on the centroid of the section. When the cross section design and the structure optimization improvement are carried out on the gimbal ring at present, the structural optimization improvement is limited by the existing manufacturing process, the improvement scheme is still designed based on the 'empirical' thinking, the structures such as the weight reducing holes, the reinforcing ribs, the welding patches and the like are used for reducing the weight and enhancing the torsion and bending bearing capacity, and the gimbal ring is manufactured by forging, welding, machining and other means, so that the gimbal ring is multiple in processing procedures and long in production period, and the welding deformation possibly affects the qualification rate and the reliability of products.
The additive manufacturing technology is used as one of advanced manufacturing technologies, adopts a discrete/stacking principle to change the three-dimensional manufacturing process of the part into two-dimensional manufacturing, is not limited by the complexity of the part structure, has the characteristic of realizing 'function priority design', and can be perfectly fused with a lightweight technology. The method for designing the gimbal structure in the lightweight mode is suitable for the additive manufacturing forming technology, the advantages of the additive manufacturing in the fast and short-flow integrated manufacturing can be reflected, and the performance and weight reduction can be improved through the optimal design.
Disclosure of Invention
The technical solution of the invention is as follows: based on the technical characteristics of additive manufacturing and forming, the design method for the weight reduction of the gimbal structure is provided, the design of the optimal force transmission path of the gimbal structure and the weight reduction model under the material distribution is realized, and a brand new method is provided for the optimization of the gimbal structure of large-size frames and the weight reduction.
The technical scheme adopted by the invention is as follows: a design method for the light weight of a gimbal structure suitable for additive manufacturing forming technology comprises the following steps:
(1) Establishing a gimbal topological optimization initial model, and selecting an optimization area;
(2) Setting physical parameters of a gimbal material, establishing boundary constraint conditions, and applying stress working conditions on a gimbal topological optimization initial model;
(3) Meshing the initial model of the gimbal ring;
(4) Setting an optimization target and additive manufacturing process constraint, and carrying out statics optimization analysis on the gimbal structure;
(5) Analyzing the structural rationality of the initial model of the gimbal topological optimization, and reconstructing a gimbal CAD model according to the additive manufacturing forming constraint and the forming mode;
(6) Adding a Lattice structure at a web position to obtain a gimbal optimization model with a Lattice structure;
(7) And establishing a gimbal CAD final model, and carrying out simulation analysis on the model to verify whether the model meets the design requirements.
In the step (1), when an optimization area is selected, the integral outline size of the initial model of the gimbal topological optimization is ensured to be the same as that of the existing model, bearing holes around and within 20-25 mm along the radial direction are used as non-design optimization areas, and the rest structures are used as optimization areas.
In the step (2), physical parameters of the high-strength stainless steel material for the gimbal ring are input into lightweight design software, wherein the physical parameters comprise Young modulus, poisson's ratio, density and yield stress; and selecting a zero state of the gimbal ring for structural optimization, taking two bearing holes in the X or Y direction of an initial model of the gimbal ring topological optimization as fixed constraint ends, and taking the other two symmetrical bearing holes as stress ends, and applying corresponding load, wherein the load is the difference between the separation force of a hose and the thrust on the ground of the engine.
In the step (3), 4 surface body units with 10 points are selected for statics optimization analysis, the grid size of the dividing unit is respectively set to be 1/3-1/6 of the wall thickness size of the gimbal ring, simulation analysis is carried out under the boundary conditions and the load working conditions set in the step (2), and stress and displacement results under different grid size dividing are compared to judge the grid convergence.
In the step (4), a shapable suspension plane angle and central symmetry constraint of additive manufacturing are set for an optimization area, the shapable suspension plane angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by taking weight reduction of 10-50% as an optimization target, and the obtained topological optimization structural integrity, stress and displacement calculation data are compared to select a topological structure with an intact force transmission path and minimum stress deformation.
In the step (5), the determined initial model structure of the gimbal topological optimization is analyzed, a three-dimensional gimbal model is formed by cladding and fitting in CAD (computer aided design) solid modeling, polyNURBS polygon modeling and NURBS curved surface modeling modes, the thickness of a rod is optimized, the size of a transition fillet is optimized, and after the completion, the forming placement position, the size of a suspension area and the forming difficulty of the additive manufacturing of the reconstructed gimbal model are analyzed, and the chamfer size of a transition part is optimized.
In the step (6), redesigning and optimizing a weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in each side web, extracting an added Lattice structure of the area, wherein the adopted Lattice structure consists of rhombic dodecahedron cells, eight extension ribs extend outwards along a body diagonal, the included angle between each main rib and a projection surface is 41-45 degrees, the length of a single cell structure rod is 3-7 mm, the diameter of the 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 carrying out 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 statics analysis, stress deformation data with a lightweight structure designed are calculated, 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 gimbal structure lightweight design method suitable for additive manufacturing forming technology, which is characterized in that through analyzing structural characteristics and stress working conditions of a gimbal product, an initial model suitable for gimbal topological optimization is established, an optimal design area is determined, and by combining statics optimization, an optimal force transmission path of the gimbal and an initial material distribution model are obtained, and design criteria considering the optimal topological structure of the gimbal and good forming quality balance condition are provided, so that a brand-new lightweight design model structure based on additive manufacturing is obtained.
(2) Compared with the original scheme, the weight of the obtained design structure for manufacturing the gimbal ring additive is reduced by 15%, the Von Mises stress is reduced by 10%, the deformation displacement is less than 1mm, and the structure is suitable for integrated forming of the additive manufacturing without machining.
Drawings
FIG. 1 is a schematic diagram of a gimbal initial design model provided by 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 diagram of a gimbal.
Detailed Description
A design method for the light weight of the gimbal structure suitable for the additive manufacturing shaping technology includes such steps as analyzing the structural characteristics, boundary conditions and stress conditions of gimbal product, building the initial model suitable for the topological optimization of gimbal, determining optimal design area, and combining with statics optimization to obtain optimal force transmission path of gimbal and initial model of material distribution. The method comprises the following specific steps:
(1) A gimbal topological optimization initial model and an optimization area design;
(2) Establishing physical parameters and boundary constraint conditions of the gimbal material and applying stress working conditions;
(3) Meshing the initial model of the gimbal ring;
(4) Setting an optimization target and additive manufacturing process constraint, and carrying out 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 the additive manufacturing forming constraint and the forming mode;
(6) Adding a Lattice structure at the web position to complete the redesign of the gimbal optimization model;
(7) And performing simulation analysis and verification on the final model of the gimbal CAD.
In the step (1), a plurality of lightening holes and reinforcing ribs are distributed in the conventional model structure of the gimbal ring, the force transmission path is shaped, and no space for continuous optimization is provided, so that the original model needs to be built again. 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 the machining and thrust chambers, the overall outline size is set to be the same as that of the existing model, the peripheral bearing holes and the radial direction are within 20-25 mm and serve as non-design optimization areas, and the rest structures serve as optimization spaces.
In the step (2), physical parameters such as Young's modulus, poisson's ratio, density, yield stress and the like of the high-strength stainless steel material for the gimbal ring 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, and taking the other two symmetrical bearing holes as stress ends, and 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 body units with 10 points are selected for hydrostatic optimization analysis, the grid size of the dividing unit is respectively 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), and stress and displacement results under different grid size dividing are compared to judge the grid convergence.
In the step (4), a shapable suspension surface angle and central symmetry constraint of additive manufacturing are set for an optimization area, the shapable suspension surface angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by taking weight reduction of 10-50% as an optimization target, and topology structures with good force transmission paths and small stress deformation are selected by comparing the obtained topology optimization structural integrity with stress and displacement calculation data.
In the step (5), the determined topological optimization initial model structure is analyzed, a high-quality three-dimensional model with smooth surface and favorable for processing is coated and fitted by utilizing CAD (computer aided design) entity modeling, polyNURBS (non-uniform resource locator) polygon modeling and NURBS curved surface modeling modes, the sizes of rod thickness, transition fillets and the like are optimized, and after the completion, the forming and placing positions, the size of a suspension area and the forming difficulty of the additive manufacturing of the reconstructed gimbal model are analyzed, and the sizes of transition part chamfers and the like are optimized.
In the step (6), redesigning and optimizing a weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in each side web, extracting an added Lattice structure of the area, wherein the adopted Lattice structure consists of rhombic dodecahedron cells, eight extension ribs extend outwards along a body diagonal, the included angle between each main rib and a projection surface is 41-45 degrees, the length of a single cell structure rod is 3-7 mm, the diameter of the 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 certain density; and carrying out 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 final model of the gimbal is subjected to statics analysis according to the boundary conditions and the load working conditions set in the step (2), stress deformation data of the lightweight structure is calculated and designed, and whether the requirement is met or not is checked.
Further description of specific embodiments follows:
for the original model of the mechanical processing of the gimbal ring shown in fig. 1, 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 and thrust chambers, a frame structure with the overall outline dimension of 482mm multiplied by 150mm is arranged, the peripheral bearing holes are kept unchanged in dimension, and the peripheral bearing holes are used as non-design optimization areas within 20mm along the radial direction of the bearing holes, and the rest structures are used as optimization spaces.
And inputting physical parameters such as Young modulus, poisson' S 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 and the other two symmetrical bearing holes in the Y direction as stress ends, and applying corresponding load which is the difference between the separation force of the hose and the ground thrust of the engine. The method comprises the steps of selecting 4-plane body units with 10 points for grid division, setting the grid size of the division units to be 6mm, setting the angle of a shapable suspension surface of additive manufacturing and central symmetry constraint for an optimized region, setting the angle of the shapable suspension surface to be 40 degrees, respectively carrying out structural statics simulation analysis by taking weight reduction of 10%, 20% and 40% as optimization targets, comparing the obtained topological optimization structural integrity with stress and displacement calculation data, and selecting a topological structure with an intact force transmission path and smaller stress deformation. And analyzing the determined topological optimization initial model structure, coating and fitting the topological optimization initial model structure into a high-quality three-dimensional model with smooth surface and favorable for processing by using CAD (computer aided design) solid modeling, polyNURBS polygon modeling and NURBS curved surface modeling modes, optimizing the dimensions, and analyzing the forming and placing positions, the size of a suspension area and the forming difficulty of the additive manufacturing of the reconstructed gimbal model after finishing the dimensions, such as chamfering of a transition part, and the like. The optimization weight reduction area is redesigned for the gimbal ring, a continuous area with the Von Mises stress value smaller than 500MPa in each side web is divided, a Lattice structure is added in the area, the Lattice structure is composed of rhombic dodecahedron cells, eight extension ribs extend outwards along a body diagonal, the included angle between each main body rib and a projection surface is 41 degrees, the length of a single cell structure rod is 3-7 mm, the diameter of the rod is 1.5mm, and the Lattice structure is arranged in a specified direction to form a regular three-dimensional space array with certain density, as shown in figure 2; and carrying out Boolean combination on the formed three-dimensional space array and the gimbal model to obtain the gimbal model with the lattice structure. And carrying out statics analysis on the final model of the gimbal according to the boundary conditions and the load working conditions, calculating stress deformation data of the designed lightweight structure, and checking whether the requirement is met.
What is not described in detail in the present specification is a well known technology to those skilled in the art.
Claims (8)
1. The design method for the light weight of the gimbal structure suitable for the additive manufacturing forming technology is characterized by comprising the following steps of:
(1) Establishing a gimbal topological optimization initial model, and selecting an optimization area;
(2) Setting physical parameters of a gimbal material, establishing boundary constraint conditions, and applying stress working conditions on a gimbal topological optimization initial model;
(3) Meshing the initial model of the gimbal ring;
(4) Setting an optimization target and additive manufacturing process constraint, and carrying out statics optimization analysis on the gimbal structure;
(5) Analyzing the structural rationality of the initial model of the gimbal topological optimization, and reconstructing a gimbal CAD model according to the additive manufacturing forming constraint and the forming mode;
(6) Adding a Lattice structure at a web position to obtain a gimbal optimization model with a Lattice structure;
(7) And establishing a gimbal CAD final model, and carrying out simulation analysis on the model to verify whether the model meets the design requirements.
2. The method for designing a gimbal structure for use in additive manufacturing forming technology according to claim 1, wherein the method comprises the steps of: in the step (1), when an optimization area is selected, the integral outline size of the initial model of the gimbal topological optimization is ensured to be the same as that of the existing model, bearing holes around and within 20-25 mm along the radial direction are used as non-design optimization areas, and the rest structures are used as optimization areas.
3. A gimbal structure lightweight design method suitable for additive manufacturing forming technology as claimed in claim 1 or 2, wherein: in the step (2), physical parameters of the high-strength stainless steel material for the gimbal ring are input into lightweight design software, wherein the physical parameters comprise Young modulus, poisson's ratio, density and yield stress; and selecting a zero state of the gimbal ring for structural optimization, taking two bearing holes in the X or Y direction of an initial model of the gimbal ring topological optimization as fixed constraint ends, and taking the other two symmetrical bearing holes as stress ends, and applying corresponding load, wherein the load is the difference between the separation force of a hose and the thrust on the ground of the engine.
4. A gimbal structure lightweight design method suitable for additive manufacturing forming technology as claimed in claim 3, wherein: in the step (3), 4 surface body units with 10 points are selected for statics optimization analysis, the grid size of the dividing unit is respectively set to be 1/3-1/6 of the wall thickness size of the gimbal ring, simulation analysis is carried out under the boundary conditions and the load working conditions set in the step (2), and stress and displacement results under different grid size dividing are compared to judge the grid convergence.
5. The method for designing a gimbal structure for use in additive manufacturing forming technology according to claim 4, wherein the method comprises the steps of: in the step (4), a shapable suspension plane angle and central symmetry constraint of additive manufacturing are set for an optimization area, the shapable suspension plane angle is set to be 35-45 degrees, structural statics simulation analysis is carried out by taking weight reduction of 10-50% as an optimization target, and the obtained topological optimization structural integrity, stress and displacement calculation data are compared to select a topological structure with an intact force transmission path and minimum stress deformation.
6. The method for designing a gimbal structure for use in additive manufacturing forming technology according to claim 5, wherein the method comprises the steps of: in the step (5), the determined initial model structure of the gimbal topological optimization is analyzed, a three-dimensional gimbal model is formed by cladding and fitting in CAD (computer aided design) solid modeling, polyNURBS polygon modeling and NURBS curved surface modeling modes, the thickness of a rod is optimized, the size of a transition fillet is optimized, and after the completion, the forming placement position, the size of a suspension area and the forming difficulty of the additive manufacturing of the reconstructed gimbal model are analyzed, and the chamfer size of a transition part is optimized.
7. The method for designing a gimbal structure for use in additive manufacturing forming technology according to claim 6, wherein the method comprises the steps of: in the step (6), redesigning and optimizing a weight reduction area for the gimbal ring, dividing a continuous area with a Von Mises stress value smaller than 500MPa in each side web, extracting an added Lattice structure of the area, wherein the adopted Lattice structure consists of rhombic dodecahedron cells, eight extension ribs extend outwards along a body diagonal, the included angle between each main rib and a projection surface is 41-45 degrees, the length of a single cell structure rod is 3-7 mm, the diameter of the 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 carrying out 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 for designing a gimbal structure for use in additive manufacturing forming technology according to claim 7, wherein: 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 statics analysis, stress deformation data with a lightweight structure designed are calculated, and whether the design requirements are met is checked.
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| CN112800655B (en) * | 2021-02-02 | 2022-02-11 | 北京科技大学 | Large and medium-sized part light weight design method based on generative optimization and guided reconstruction |
| CN114178553B (en) * | 2021-11-30 | 2022-10-25 | 西安交通大学 | Method and system for determining optimal forming direction of workpiece in additive manufacturing process |
| CN116341336B (en) * | 2023-03-30 | 2024-02-20 | 之江实验室 | Topology reconstruction method and model for human-simulated robot calf |
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