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Optimization, Fabrication and Testing of Novel Lightweight Solutions for Aircraft Structure Components based on 3D-Printing and Fiber-Composites
An aircraft aileron structure shall be designed based on a carbon fiber lattice system, relying on modern optimization algorithms developed at CMAS Lab. The part shall be manufactured with a novel manufacturing method, tested and compared to the original Do-228 component.
As part of ETH’s Strategic Focus Area: Advanced Manufacturing, CMASLab and other research groups are investigating cost-efficient ultra-lightweight structures. These types of structures are achieved by a combination of Additive Manufacturing (AM) and Carbon Fiber Reinforced Polymers (CFRP) processes.
Comparing the classic differential design approach of a Do-228 twin-turboprop utility aircraft, as can be seen above, many joints and connecting elements are adding undesired mass and complexity to the structure. The aileron consists of twelve CFRP parts, which are joined by gluing. The aileron has 21 bond lines, thus making the assembly of the part complex and prone to errors.
With a novel design method, it is possible to combine the advantages of the complexity for free approach of additive manufacturing with the high load carrying ability of fiber reinforced composite structures. The structure will become tunable and its manufacturing can be reduced in steps and complexity. The novel AM-Composite design is based on 3D-printed lost male tooling and a carbon fiber lattice approach which allows complete design freedom as well as the realization of an ultra-lightweight component. Furthermore the manufacturing steps are drastically reduced. With the feasibility of the concept already proven, the developed methods shall now be combined into a load carrying aircraft structure based on loads and geometry of the Do-228 so that the competitiveness of the novel design can be shown.
As part of ETH’s Strategic Focus Area: Advanced Manufacturing, CMASLab and other research groups are investigating cost-efficient ultra-lightweight structures. These types of structures are achieved by a combination of Additive Manufacturing (AM) and Carbon Fiber Reinforced Polymers (CFRP) processes. Comparing the classic differential design approach of a Do-228 twin-turboprop utility aircraft, as can be seen above, many joints and connecting elements are adding undesired mass and complexity to the structure. The aileron consists of twelve CFRP parts, which are joined by gluing. The aileron has 21 bond lines, thus making the assembly of the part complex and prone to errors. With a novel design method, it is possible to combine the advantages of the complexity for free approach of additive manufacturing with the high load carrying ability of fiber reinforced composite structures. The structure will become tunable and its manufacturing can be reduced in steps and complexity. The novel AM-Composite design is based on 3D-printed lost male tooling and a carbon fiber lattice approach which allows complete design freedom as well as the realization of an ultra-lightweight component. Furthermore the manufacturing steps are drastically reduced. With the feasibility of the concept already proven, the developed methods shall now be combined into a load carrying aircraft structure based on loads and geometry of the Do-228 so that the competitiveness of the novel design can be shown.
An aircraft aileron structure shall be designed based on a carbon fiber lattice system, relying on modern optimization algorithms developed at CMAS Lab. The part shall be manufactured with the novel method, tested and compared to the original Do-228 component. This covers:
• Literature research and familiarization with lattice structures and aircraft structure components
• Introduction into finite element software and optimization algorithm
• Implementation of given load cases of the Do-228 into the optimization algorithm and evaluation of results
• Final design of the structure, including load introductions and layup
• Manufacturing of a composite demonstrator for testing based on a developed manufacturing concept
• Verify simulations/load carrying ability with an experiment and compare to existing solutions
An aircraft aileron structure shall be designed based on a carbon fiber lattice system, relying on modern optimization algorithms developed at CMAS Lab. The part shall be manufactured with the novel method, tested and compared to the original Do-228 component. This covers:
• Literature research and familiarization with lattice structures and aircraft structure components
• Introduction into finite element software and optimization algorithm
• Implementation of given load cases of the Do-228 into the optimization algorithm and evaluation of results
• Final design of the structure, including load introductions and layup
• Manufacturing of a composite demonstrator for testing based on a developed manufacturing concept
• Verify simulations/load carrying ability with an experiment and compare to existing solutions
Arthur Schlothauer, Dominic Keidel
arthursc@ethz.ch, keideld@ethz.ch
Arthur Schlothauer, Dominic Keidel arthursc@ethz.ch, keideld@ethz.ch