Topology optimization design of aviation blade structure based on selective laser melting technology

Due to the limitation of traditional manufacturing technology, the topology optimization of aviation blade has been difficult to meet the requirements of high service performance and lightweight. A topology optimization design method of aviation blade based on selective laser melting technology is proposed, which considers the self-supporting overhang and the minimum size constraints of additive manufacturing to achieve the topology optimization design of blade. Aiming at the problem that the size and position of the holes inside the topological blade could not be accurately determined, the internal structure of the topological blade is projected using the projection method, and the topological structure is transformed into point cloud data. By considering the SLM process constraints, curve fitting and Boolean operation are adopted to reconstruct the topological results of the internal structure of the blade. The simulation analysis of mechanics and SLM printing results show that the overall stiffness of the blade increases and the maximum stress value is reduced to 367.51 MPa after the topology optimization; thus the selective laser melting technology can be used to realize the manufacture of the topology blade. Finally, the selective laser melting technology is used to manufacture the topology of blade, the experimental results show that the topological structure of the blade fully conforms to the additive manufacturing process standard, blade weight is reduced by 24.5%, the tensile strength and yield strength are 950 MPa and 780 MPa, respectively, and the mechanical properties are better than the traditional casting standard, which verifies the mechanical properties and lightweight effect of the aviation blade after topology optimization.