Session: 03-03-04: Annual Congress-Wide Symposium on Additive Manufacturing IV

Paper Number: 166954

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF 

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly in reducing the number of parts made with multistage combined technologies, which often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom of creating complex geometries, with and without need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by debinding and sintering process, as an alternative to powder bed approaches. Furthermore, DfAM principles are discussed to minimize the need for support, enable easy post-processing to achieve better surface finish in component design, particularly to meet high tolerances for aerospace and healthcare applications.

In this paper, we explore the current state of the art in design for additive manufacturing (DfAM) for the aerospace industry to develop strategies for simplifying the challenges of fabricating intricate features and complex geometries. This include applying DfAM principles and topology optimization to reduce the weight of the GE engine bracket without compromising part performance in terms of structural rigidity and functionality, covering support assessment, fill density, material selection, and process optimization to improve manufacturability. We have performed topology optimization (TO) on the Jet engine bracket in the SOLIDWORKS 2024 R2 and validated the design under the standard loading conditions for Jet engine. Topology Optimization (TO) is performed in a high-fidelity environment, achieving weight reductions of 44%, 50%, and 60% of the original bracket design, followed by simulations to ensure structural rigidity and preservation of clamping features. The 3D-printed parts from TO on the metal FFF has been evaluated through precision in realizing filling radii (compared with CAD models), accuracy in holes, cavities, dimensional accuracy, and process efficiency.

To conclude, Topology Optimization principles have been successfully applied to the GE jet engine bracket and validated under the applied loading conditions, achieving a 60% weight reduction from the original design while maintaining mechanical strength. The dimensional accuracy analysis of 3D printed brackets further demonstrates the manufacturability and capabilities of metal-Fused Filament Fabrication technology for aerospace applications.

Presenting Author: Abhishek Singh University of Michigan Ann Arbor

Presenting Author Biography: I am a Doctor of Engineering candidate in Manufacturing within the Mechanical Engineering Department at the University of Michigan, focusing on additive manufacturing technologies, materials processing, sheet metal forming and workforce development through additive manufacturing education and training.

Authors:

Abhishek Singh University of Michigan Ann Arbor
Luohaoran Wang University of Michigan Ann Arbor
Abdul Sayeed Khan ORNL
Aren Vardhan Pilli University of Michigan
Mihaela Banu University of Michigan Ann Arbor