Purpose
This paper aims to summarize design rules based on the process characteristics of selective laser melting (SLM) and structural optimization and apply the design rules in the lightweight design of an aluminum alloy antenna bracket. The design goal is to reduce 30 per cent of the weight while maintaining the stress levels in the original part.
Design/methodology/approach
To reduce weight as much as possible, the titanium alloy with higher specific strength was selected during the process of optimization. The material distribution of the bracket was improved by the topology optimization design. The redesign for SLM was used to obtain an optimization model, which was more suitable for SLM. The component performance was improved by shape optimization. The modal analysis data of the structural optimization model were compared with those of the stochastic lightweight model to verify the structural optimization model. The scanning data were compared with those of the original model to verify whether the model was suitable for SLM.
Findings
Structural optimization design for antenna bracket realized the mass decrease of 30.43 per cent and the fundamental frequency increase of 50.18 per cent. The modal analysis data of the stochastic lightweight model and the structural optimization model indicated that the optimization performance of structural optimization method was better than that of the stochastic lightweight method. The comparison results between the scanning data of the forming part and the original data confirmed that the structural optimization design for SLM lightweight component could achieve the desired forming accuracy.
Originality/value
This paper summarizes geometric constraints in SLM and derives design rules of structural optimization based on the process characteristics of SLM. SLM design rules make structural optimization design more reasonable. The combination of structural optimization design and SLM can improve the performance of lightweight antenna bracket significantly.
Effects of Structural Parameters on the Poisson's Ratio and Compressive Modulus of 2D Pentamode Structures Fabricated by Selective Laser Melting
