Optimal Design And Process Reaserch Of Aluminium Alloy Bracket Based On SLM Fabricating

Metal Additive Manufacturing(MAM)gradually becomes a mature approach of manufacturing relying on its advantages in fabricating intricate structures effectively.MAM reveals its superiorities in overcoming difficulties of traditional manufacturing processes in domains of auto,biomedicine,aerospace,etc.MAM is capable of fabricating complex structures integrally to reduce connections and connection processes and making the shapes that traditional means can't achieve.This paper firstly studied the performance of laser selective melting(SLM)experimentally by molding specific-feature models and the related SLM process parameters were obtained.Based on the actual work conditions and geometrical features of original structure,structure,constrains and loads of the bracket were simulated and analyzed to obtain the results about stress,strain,stiffness and eigen frequencies under specific working conditions by finite element method.Then,to satisfy the requirements of performance,various optimized results were obtained by utilizing topology optimization to formulate various design schemes.Guided by the principles of SLM process,optimal high-rigidity structures were designed though making use of complex surfaces modeling.In order to meet demands of fabricating and performance,optimal structures were repeatedly adjusted with shape optimization and grid-morphing technologies.In this paper,the optimal design was compared with the original design by using the same parameters.The SLM manufacturability and the advantages of the optimized structure were verified.The experience for optimization design of thin-wall structure was summarized.The final design of the X axis,Y axis and Z axis maximum displacement were reduced by 16.2%,9.7% and 47.5% respectively,the maximum displacement under the condition of 10 times gravity was reduced by 17.1%,the first order eigen frequency was increased by 35%,the second order eigen frequency was increased by 41%,while the mass was slashed by 25.6%.The optimization structure reduced the fabricating volume,time and risk.