Improvement of engine bracket design by using topology optimization and additive manufacturing

Engine bracket plays a crucial part especially in aerospace industry where the mass of bracket affected the performance of aircraft. However, reduction in mass might affected the performance of the bracket. Topology optimization (TO) is a process of optimizing the material by a given design space in...

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Main Author:	Said, Zaitul Akma
Format:	Thesis
Language:	English English
Published:	2018
Subjects:	T Technology (General)
Online Access:	http://eprints.utem.edu.my/id/eprint/21458/1/Improvement%20Of%20Engine%20Bracket%20Design%20By%20Using%20Topology%20Optimization%20And%20Additive%20Manufacturing.pdf http://eprints.utem.edu.my/id/eprint/21458/2/Improvement%20of%20engine%20bracket%20design%20by%20using%20topology%20optimization%20and%20additive%20manufacturing.pdf
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spelling	my-utem-ep.214582022-06-13T10:36:42Z Improvement of engine bracket design by using topology optimization and additive manufacturing 2018 Said, Zaitul Akma T Technology (General) TA Engineering (General). Civil engineering (General) Engine bracket plays a crucial part especially in aerospace industry where the mass of bracket affected the performance of aircraft. However, reduction in mass might affected the performance of the bracket. Topology optimization (TO) is a process of optimizing the material by a given design space in response to the set of loads, boundary conditions and constraints in order to maximize the performance. TO result produces complex geometry while additive manufacturing (AM) is a technology to manufacture complex model. The purpose of this study is to obtain a fully optimized lightweight of engine bracket design with capability to withstand the load of the engine by using topology optimization technique.In addition, the effect of manufacturability when incorporating topology optimization in additive manufacturing would also be investigated. In order to minimize the mass and maintaining the stiffness of the bracket, topology optimization by SolidThinking Inspire has been applied on two different design spaces which were named by Topology Optimization I (TO I) and Topology Optimization II (TO II). A baseline of target specification on AM outputs which are printing time, raw material mass and support material mass has been obtained by using CreatWare V6.4.3 from a total of 300 existing topology optimized designs of engine bracket from GrabCAD. Remodelling on topology optimized design was done by CATIA V5R20 based on TO and AM constraints in order to fit in the target specification baseline. AM was applied in order to demonstrate the manufacturability for topology optimized design by using Fused Depostion Modelling (FDM) 3D printer with ABS material. In addition, the modification on unsmoothed geometry produced by TO was developed in order to make the design feasible to be manufactured. The result of the study showed the mass of the optimized design was 52% less compared to original design without sacrificing the performance since the von Mises stress of the optimized design was slightly different compare to original design. Based on the study, fabrication of topology optimized design using AM was considered successful but support material was still required for complex geometry produced by TO. 2018 Thesis http://eprints.utem.edu.my/id/eprint/21458/ http://eprints.utem.edu.my/id/eprint/21458/1/Improvement%20Of%20Engine%20Bracket%20Design%20By%20Using%20Topology%20Optimization%20And%20Additive%20Manufacturing.pdf text en public http://eprints.utem.edu.my/id/eprint/21458/2/Improvement%20of%20engine%20bracket%20design%20by%20using%20topology%20optimization%20and%20additive%20manufacturing.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=107295 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Mechanical Engineering Ramli, Faiz Redza
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Ramli, Faiz Redza
topic	T Technology (General) T Technology (General)
spellingShingle	T Technology (General) T Technology (General) Said, Zaitul Akma Improvement of engine bracket design by using topology optimization and additive manufacturing
description	Engine bracket plays a crucial part especially in aerospace industry where the mass of bracket affected the performance of aircraft. However, reduction in mass might affected the performance of the bracket. Topology optimization (TO) is a process of optimizing the material by a given design space in response to the set of loads, boundary conditions and constraints in order to maximize the performance. TO result produces complex geometry while additive manufacturing (AM) is a technology to manufacture complex model. The purpose of this study is to obtain a fully optimized lightweight of engine bracket design with capability to withstand the load of the engine by using topology optimization technique.In addition, the effect of manufacturability when incorporating topology optimization in additive manufacturing would also be investigated. In order to minimize the mass and maintaining the stiffness of the bracket, topology optimization by SolidThinking Inspire has been applied on two different design spaces which were named by Topology Optimization I (TO I) and Topology Optimization II (TO II). A baseline of target specification on AM outputs which are printing time, raw material mass and support material mass has been obtained by using CreatWare V6.4.3 from a total of 300 existing topology optimized designs of engine bracket from GrabCAD. Remodelling on topology optimized design was done by CATIA V5R20 based on TO and AM constraints in order to fit in the target specification baseline. AM was applied in order to demonstrate the manufacturability for topology optimized design by using Fused Depostion Modelling (FDM) 3D printer with ABS material. In addition, the modification on unsmoothed geometry produced by TO was developed in order to make the design feasible to be manufactured. The result of the study showed the mass of the optimized design was 52% less compared to original design without sacrificing the performance since the von Mises stress of the optimized design was slightly different compare to original design. Based on the study, fabrication of topology optimized design using AM was considered successful but support material was still required for complex geometry produced by TO.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Said, Zaitul Akma
author_facet	Said, Zaitul Akma
author_sort	Said, Zaitul Akma
title	Improvement of engine bracket design by using topology optimization and additive manufacturing
title_short	Improvement of engine bracket design by using topology optimization and additive manufacturing
title_full	Improvement of engine bracket design by using topology optimization and additive manufacturing
title_fullStr	Improvement of engine bracket design by using topology optimization and additive manufacturing
title_full_unstemmed	Improvement of engine bracket design by using topology optimization and additive manufacturing
title_sort	improvement of engine bracket design by using topology optimization and additive manufacturing
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Mechanical Engineering
publishDate	2018
url	http://eprints.utem.edu.my/id/eprint/21458/1/Improvement%20Of%20Engine%20Bracket%20Design%20By%20Using%20Topology%20Optimization%20And%20Additive%20Manufacturing.pdf http://eprints.utem.edu.my/id/eprint/21458/2/Improvement%20of%20engine%20bracket%20design%20by%20using%20topology%20optimization%20and%20additive%20manufacturing.pdf
_version_	1747834014498029568

Improvement of engine bracket design by using topology optimization and additive manufacturing

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