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Simulation, 3D Printing, and Casting: A Symbiotic Solution for Large Aerospace Structures
技术
- 分析与建模 - 数字孪生/模拟
适用行业
- 航天
- 设备与机械
适用功能
- 维护
- 产品研发
用例
- 添加剂制造
- 制造过程模拟
服务
- 系统集成
- 测试与认证
挑战
航空航天业不断寻求减少质量和燃料消耗的方法，而增材制造或 3D 打印在这方面提供了巨大的潜力。然而，该技术在航空领域相对较新，并且面临认证和资格问题。此外，3D 打印机的尺寸限制了其在较大部件（例如飞机门）上的使用。面临的挑战是结合增材制造和铸造方法来设计飞机检修门。由于其尺寸和复杂性，该门为通过一次性生产方法降低成本提供了一个有希望的机会。然而，门太大，无法使用直接金属激光烧结 (DMLS)，它是由 AS7G06 铝制成的，这种铝尚未在使用 DMLS 的航空领域获得资格，并且它的蒙皮非常薄，尺寸和几何公差非常严格。
关于客户
SOGECLAIR 航空航天隶属于 SOGECLAIR SA 集团，是航空航天业的主要工程合作伙伴和主承包商。该公司提供配置管理、航空结构、系统安装、飞机内饰、制造工程和设备方面的咨询和管理服务。其活动从研究和开发阶段延伸到产品供应。 SOGECLAIR 航空航天还通过其子公司和合资企业提供生产服务：AviaComp、ADM、MSB 和 PrintSky。生产的零件包括用于空客 A350 和庞巴迪 C 系列的使用 CFRP 的油箱检修门、用于空客 A380 的金属地板结构以及公务机机舱内饰。
解决方案
Sogeclair 航空航天公司的工程师开发了一种将增材制造和铸造相结合来制造飞机门的工艺。他们使用 Altair 的 HyperWorks 软件套件进行设计和优化。制造过程基于 3D 打印树脂模型的熔模铸造。工程师遵循系统的路线图，以确保满足所有项目要求。他们在设计过程的概念阶段使用拓扑优化来优化给定设计空间内的材料布局。随后的有限元 (FE) 分析研究了优化设计。进行填充和凝固模拟来预测缺陷的位置和大小，例如不完整的填充区域或气泡。针对飞机检修门的代表性区域（尤其是较棘手的区域）制作了可行性样本。然后按照真实比例制造门，使用粘合剂喷射技术在 PMMA 树脂中进行 3D 打印，并在从模具中取出后进行铸造和热处理。
运营影响
数量效益
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