Study On Optimal Design And Manufacturing Process Of Functional Parts Based On Laser Additive Manufacturing

Aviation blade is one of the key components of aero-engine,most of which is solid structure.However,as a result of large centrifugal force and mass,the traditional solid aero-engine blade can not meet the the requirements of design and operation of aero-engine at present.Therefore,the design of aviation blade need to be optimized.Topology optimization can improve the mechanical properties and reduce the mass of aviation blade.Furthermore,to cope with the problem of hardly produced of complex structural components in the traditional manufacturing process which restricted the further development of aviation blade topology optimization technology,selective laser melting(SLM)is proposed to transform the complex three-dimensional problems into two-dimensional ones that are easy to deal with,and then the complex components are produced.And the development of optimization design and manufacturing of aviation blade structure is promoted.Thus,aviation blade is taken as the research object,the requirements of the high-service performance of aviation blades on its structure and forming process are analyzed deeply,and a new topology optimization design method of aviation blade for SLM is studied systematically in this thesis,and the main contents can be concluded as follows:(1)To solve the problem of the large number of non-self-supporting overhanging structures in the optimized structure caused by the traditional topology optimization design method.A new topology optimization design method of aviation blade based on variable density method for SLM is present to solve non-self-supporting problem of overhanging structures.Then,the projection and curve fitting method is introduced to achieve reconstruction of internal structure of aviation blade after topology optimization.(2)To guarantee the additive manufacturing form effect and quality of aviation blade after topology optimization,the mapping relationship between laser processing parameters and aviation blade forming quality is investigated by single factor experiment of laser process parameters with SLM manufacturing equipment.Then,the optimized process parameters of selective laser melting are determined by the orthogonal experiment to lay the foundation for the subsequent aviation blade SLM process.(3)In order to verify the validity and feasibility of the topology optimization design method of aviation blade proposed in this thesis,the optimized aviation blade is manufactured by SLM process using the optimal process parameters.Then,quality test and tensile property test is introduced to verify the lightweight effect as well as the mechanical properties of the optimized aviation blade.This work focuses on the topology optimization design method of aviation blade based on the selective laser melting process,and the aviation blade is optimized.Then,mechanics,SLM process simulation and 3D printing experiments based on SLM are adopted to verify topology optimized aviation blade.