Research On Topology Optimization Technology For Satellite Parts Process Design

In modern aircraft manufacturing project, in order to minimize the weight of the structure and increase the load-carrying capacity, the high-strength and thin-walled aluminum alloy parts are widely used in aircraft design and manufacturing processes. Because of the complex structure and the wall’s thin thickness, parts usually are machined in the milling centers. In this process, majority of the rough material needs to be removed, which leads to deterioration of parts becomes weakly. And machining distortion generated in the process. In this paper, based on the previous research about thin-walled parts’ deformation in the process of machining, make the relationship between load paths under the external loading conditions and machining distortion the main research content and take advantage of topology optimization and finite element simulation to research of thin-walled parts machining distortion prediction. The main work is as follows:1. Described the background and significance of the research and summarized the status of the deformation prediction and control about thin-walled parts at home and abroad. Based on the detailed analysis about the factors of part’s deformation in the machining process, make sure of the content and the overall framework of this paper.2. Described the optimization program of the thin-walled parts’ clamping and make the topology optimization apply to the machining process innovative and seek the force transmission path formed by the clamping force in the machining process through the topology optimization. By analyzing and comparing different load paths formed by different clamping programs, study the relationship between the part deformation and the load path parts damaged or not.3. This section describes the principle of residual stress test by the X-ray diffraction method and make theoretical analysis of the milling distortion caused by blank residual stress. Make analysis of internal stress and the law of machining distortion in the milling process by theoretical mechanics. Make a simulation of calculation process through the FEM software and compare the two calculation results.4. In the Thin-walled box part case, make the research of the three dimensional finite element model’s machining distortion simulation and solve the key technology about three-dimensional finite element model, how the rough initial residual stress applied and "Birth and death" method to simulate material removal process.5. Summing up the above technologies, make simulation about the satellite’s frame make by aluminum and make the machining experiment and make analysis of machining distortion about the thin-walled parts caused by the blank residual stress and load path’s damage.