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Optimizing novel multi-scaled simulation method for deviation analysis of generatively designed aileron bracket using laser powder bed fusion

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Abstract

This research is devoted to forecast the distortion of aileron brackets by means of generative design (GD) and multi-scaled numerical simulation comprising meso- and macro-scaled simulation based on thermomechanical method (TMM) and inherent strain method (ISM), respectively. The multi-scaled simulation began with TMM-based virtual calibration test (VCT) including mesh sensitivity and volume fraction analysis to identify the best meshing voxel size. In finding inherent strain tensors, optimization was implemented using pattern search algorithm referring to the minimum relative error. Further, macro-scaled simulation was implemented to estimate bracket distortion behavior by applying the inherent strain tensors in ISM. For experiment, the conventional aileron bracket shape was first improved by complying the internal rules of GD throughout the desired design space with respect to stress goal and weight reduction based on iterative material distribution. After obtaining the new generatively designed component, linear static analysis was implemented to improve the stress magnitude and surface smoothness level by mesh and material sculpting. Then, the component is manufactured using laser powder bed fusion with manual postprocessing of support structure followed by sand blasting. The finished aileron bracket was then measured using a 3D scanner GOM Atos Q. As conclusion, this novel multi-scaled simulation method based on GD, static stress, and virtual calibration test allows a forecast of an acceptable surface deviation within relative single point and mean errors up to 11% and 5% respectively. By neglecting the tedious and time-consuming procedure of real calibration, a huge time reduction for preparation up to a few days and for computation up to 35% compared to pure TMM can be achieved.

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Acknowledgements

The authors would like to express their gratitude to staff members of Smart Manufacturing Research Institute (SMRI) and Research Interest Group: Advanced Manufacturing Technology (RIG:AMT) at School of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Shah Alam, as well as Professorship of Virtual Production Engineering at Chemnitz University of Technology (CUT) in Germany for encouraging this research.

Funding

There was partial funding for this study. This research is financially supported by Konsortium Kecemerlangan Penyelidikan Grant Scheme (Large Volume Additive Manufacturing/LVAM, No. KKP001A-2021) from the Ministry of Higher Education (MOHE) in Malaysia and Geran Penyelidikan Khas (Correlation of Distortion and Deformability in Hollow 316L Wire Arc Additive Manufacturing (WAAM) Model Based Numerical Simulation, No. 600-RMC/GPK 5/3 123/2020) from UiTM.

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Authors and Affiliations

  1. Smart Manufacturing Research Institute (SMRI) and School of Mechanical Engineering, Universiti Teknologi MARA (UiTM), Shah Alam, Selangor, Malaysia

    Yupiter H. P. Manurung, Thoufeili Taufek & Mohd Shahriman Adenan

  2. Universitas Sumatera Utara, Medan, Indonesia

    Yupiter H. P. Manurung

  3. Centre of Smart System and Innovative Design (CoSSID), Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Melaka, Malaysia

    Nur Izan Syahriah Hussein

  4. 3D Gens Sdn Bhd, Shah Alam, Selangor, Malaysia

    Muhd Mufqi Aminallah

  5. First Metrology Sdn Bhd, Petaling Jaya, Selangor, Malaysia

    Fitri Iskandar Jamaludin

  6. Department of Mechanical Engineering, Frederick University, Nicosia, Cyprus

    Loucas Papadakis

  7. Powder Technology & Advanced Materials Research Group, School of Engineering, HES-SO Valais-Wallis, Sierre, Switzerland

    Haifa Sallem

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  1. Yupiter H. P. Manurung
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Correspondence to Mohd Shahriman Adenan.

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Manurung, Y.H.P., Taufek, T., Adenan, M.S. et al. Optimizing novel multi-scaled simulation method for deviation analysis of generatively designed aileron bracket using laser powder bed fusion. Int J Adv Manuf Technol 132, 5855–5871 (2024). https://doi.org/10.1007/s00170-024-13714-5

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