Preliminary design of 3D printed fittings for UAV

Mieloszyk, Jacek; Tarnowski, Andrzej; Kowalik, Michał; Perz, Rafał; Rządkowski, Witold

doi:10.1108/aeat-07-2018-0182

Cited by 14 publications

(13 citation statements)

References 10 publications

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“…The main requirement is to design optimal frame, what include identify all geometry and loads assumptions (Mieloszyk et al , 2019). Missile is controlled by movement of four canards, which are assembled on shafts, supported by bearings.…”

Section: Methodsmentioning

confidence: 99%

Feasibility study of topology optimization of the control system frame for the missile with canard configuration

Abratanski

Grzejda

Perz

2023

AEAT

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Purpose The purpose of this paper is to describe the new method for optimizing the topology of the control system frame for a canard missile to create its efficient model. Determining the minimum volume of the part risked losing some of the mechanical interfaces and functionality required of the frame. The proposed method must cope with these requirements and include a validation loop of the improved solution proposed by the software. The processing of the mathematical model to a printable form must take into account manufacturing technologies limitations and appropriate curvature continuities to avoid stress concentrations. Design/methodology/approach Real examples from the aerospace industry are presented and the process of determining a prototype is described. The optimization assumed leaving the largest volume of the domain. Strength analyses were performed on both the assembly fasteners and the robust prototype. Once all boundary conditions were validated, topological optimization was performed in the ANSYS environment. The algorithm of the optimization was presented. Findings Obtained fatigues showed the vast potential of topology optimization, efficient method of weight reduction in specific situations. It can be considered as an innovative approach to the manufacturing of products with a structure focused on the best possible correlation of weight and strength, for example of a canard rocket. Originality/value The paper introduces precise manufacturing technology of the inner frame for the missile’s control system, which ensures sufficient properties of the material, known as EBM.

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Section: Methodsmentioning

confidence: 99%

Feasibility study of topology optimization of the control system frame for the missile with canard configuration

Abratanski

Grzejda

Perz

2023

AEAT

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“…AM technology can produce complex design that is impossible for achieving by using of conventional methods [2][3][4][5][6]. New geometries such as grids, cell structures in form of honeycombs and optimized structures with bionic look-a-like design can improve the overall performance of the aircraft [7][8][9][10].…”

Section: Engineeringmentioning

confidence: 99%

“…The emerging technology of additive manufacturing is entering rapidly into the aerospace world and seems to be its future. Many manufacturing processes are replaced by this technology [9]. It's already shown that with the use of additive manufacturing more complex designs, and light-weight construction of UAV components can be made, offering several advantages compared to conventional manufacturing methods [33].…”

Section: Engineeringmentioning

confidence: 99%

Implementation of Optimum Additive Technologies Design for Unmanned Aerial Vehicle Take-Off Weight Increase

Maričić¹,

Haber²,

Veljovic³

et al. 2020

Eureka: PE

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The aim of this paper is to investigate the possibility of drone optimization by selecting and testing the best material suitable for additive manufacturing technology and generative design approach, i. e. shape optimization. The use of additive manufacturing technology enables the creation of models of more complex shapes that are difficult or impossible to produce with conventional processing methods. The complex and unconventional design of the drone body can open up many possibilities for weight reduction while maintaining the strength of the drone body. By using 3D printing in addition to FEM (Finite Element Method) analysis, and generative design it can identify areas of the drone body that are overdrawn, allowing it to either lift off material or simply change the design at these areas. Choosing the right material for this application is crucial in order to optimise the mechanical properties of the material with weight, material cost, printability and availability of the material and the 3D printing method, while at the same time reducing environmental pollution. The goal is to reduce the drone mass by 15–20 % using generative design tools. Mass is an important segment when prototyping a drone. If the drone is too heavy, more lift power is needed to keep the drone in the air, so the propellers have to turn faster and use more energy. Consequently, the reduction of drone mass should increase the take-off weight. In this article 5 commercial drones of similar characteristics are compared with the final proposal of our 3D printed drone (Prototype 1). The rotor distance between the drones, the weight of the electric motor and the take-off weight are compared. The goal was to produce a prototype with a big rotor distance-to-weight ratio, and take-off weight bigger than observed drones have. The defined goal function was optimized in order to evaluate characteristics of 12 different 3D printed materials. Following properties: ultimate strength, stiffness, durability, printability of the material, and required bed and extruder temperature for printing were taken in consideration to select optimal material. Polycarbonate proved to be the best choice for 3D printing UAVs

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“…However, UAVs can afford to have a smaller safety margin on the structural side, as a human pilot is on the ground [3,15,16]. In this context, materials not typically used in the aviation industry, such as polymers and 3D-printed materials, have been incorporated for UAV structural design [17][18][19]. Composites used in the aviation industry should exhibit high-reliability characteristics, namely a high degree of mechanical, impact, and thermal resistance [20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Multidisciplinary Optimization for Weight Saving in a Variable Tapered Span-Morphing Wing Using Composite Materials—Application to the UAS-S4

et al. 2022

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This paper is a follow-up to earlier work on applying multidisciplinary numerical optimization to develop a morphing variable span of a tapered wing (MVSTW) to reduce its weight by using composite materials. This study creates a numerical environment of multidisciplinary optimization by integrating material selection, structural sizing, and topological optimization following aerodynamic optimization results with the aim to assess whether morphing wing optimization is feasible. This sophisticated technology is suggested for developing MVSTWs. As a first step, a problem-specific optimization approach is described for specifying the weight-saving structure of wing components using composite materials. The optimization was performed using several approaches; for example, aerodynamic optimization was performed with CFD and XFLR5 codes, the material selection was conducted using MATLAB code, and sizing and topology optimization was carried out using Altair’s OptiStruct and SolidThinking Inspire solvers. The goal of this research is to achieve the MVSTW’s structural rigidity standards by minimizing wing components’ weight while maximizing stiffness. According to the results of this optimization, the weight of the MVSTW was reduced significantly to 5.5 kg in comparison to the original UAS-S4 wing weight of 6.5kg. The optimization and Finite Element Method results also indicate that the developedmorphing variable span of a tapered wing can complete specified flight missions perfectly and without any mechanical breakdown.

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Preliminary design of 3D printed fittings for UAV

Cited by 14 publications

References 10 publications

Feasibility study of topology optimization of the control system frame for the missile with canard configuration

Feasibility study of topology optimization of the control system frame for the missile with canard configuration

Implementation of Optimum Additive Technologies Design for Unmanned Aerial Vehicle Take-Off Weight Increase

Multidisciplinary Optimization for Weight Saving in a Variable Tapered Span-Morphing Wing Using Composite Materials—Application to the UAS-S4

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