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Design of novel, additively manufactured cellular lattice supported composite structures using topology optimisation

使用拓扑优化设计新颖的增材制造蜂窝晶格支撑复合结构

基本信息

批准号：
2273724
负责人：
金额：
--
依托单位：
University of Bristol
依托单位国家：
英国
项目类别：
Studentship
财政年份：
2019
资助国家：
英国
起止时间：
2019 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=studentship-2273724
关键词：
Design novel additively manufactured cellular

项目摘要

Upscaling the production of wind energy capacity is of great importance domestically and globally due to three significant factors. Firstly, pollution from greenhouse gases and other emissions as a result of burning fossil fuels for energy contributes to global warming. These effects cause increased instability of the climate, resulting in more natural disasters as well as ecosystem collapse. Secondly, over-dependence on fossil fuel for energy causes insecurity and tensions between and within nations. Thirdly, increasing the installed capacity of wind energy is an economic benefit. Wind energy is highly cost efficient for producing energy and the investment in the wind industry drives economic growth due to job creation in manufacturing, construction, and operation and maintenance. The development of new technology and energy storage networks also helps to lower costs of wind and other forms of renewable energy. One of the largest barriers to faster production of wind energy capacity is the cost and lead time of manufacturing wind turbine rotor blades. The growing scale of wind blades means that the main costs of manufacturing which are associated with materials, labour, and tooling, are a limiting factor. It is proposed that manufacturing a mould which acts as the internal structure of the blade would target each of these sources of cost through enabling automation and reduced material use by removing the need for expensive steel-backed composite moulds.Additive manufacturing (AM) is an enabling technology which is crucial for producing large scale structures in future. It's main function for wind blade production is more efficient use of material and division of labour. AM enables the use of topology optimisation (TO) for the design of large structures. TO provides a means to design structures for specific performance needs. AM allows for the creation of these structures that have been customized, making the two technologies an ideal match for producing structures that are designed to meet specific needs. The combination of TO and AM leads to the creation of structures that are highly efficient with minimal waste and maximum speed in production.There are two main challenges associated with using topology optimisation in wind blade design. Firstly, the aeroelastic response of the blade is an important factor in the structural design, as it can improve the blade's ability to capture energy from the wind and alleviate loads by optimising the stiffness and tuning the natural frequencies. Topology optimisation is not readily compatible with aeroelastic solvers and there is limited research combining aeroelastic design with topology optimisation due to this difficulty. Secondly, composite laminates are critical component of large wind turbine blades, due to the size of the bending moment arms. Topology optimisation of orthotropic laminates and multiple materials is limited in its ability to design large scale, manufacturable structures, given the computationally intensive process.A design methodology is proposed, which leverages the strengths of topology optimisation and additive manufacturing to achieve optimised composite laminate configurations as well as repeated unit cell graded lattice architectures for wind turbine blades. The method involves a multi-stage topology optimisation process; In the first stage, a composite laminate structure is designed based on an idealised topology optimisation solution; In the second stage, the results from the first stage are frozen and utilised to design a 3D printed repeated unit cell architecture which supports the composite laminates and allows for improved manufacturability. The goal of this process is to combine conventional knowledge of structural requirements for efficient use of composite laminate configurations, while also enabling the inclusion of additive manufacturing to support and improve performance, weight and manufacturing cost.

由于三个重要因素，扩大风能产能的生产在国内和全球都非常重要。首先，燃烧化石燃料作为能源所产生的温室气体和其他排放物造成的污染加剧了全球变暖。这些影响增加了气候的不稳定性，导致更多的自然灾害和生态系统崩溃。第二，过度依赖化石燃料作为能源造成国家之间和国家内部的不安全和紧张局势。第三，增加风能装机容量是一种经济效益。风能在生产能源方面具有很高的成本效益，由于在制造业、建筑业以及运营和维护方面创造了就业机会，对风能行业的投资推动了经济增长。新技术和储能网络的发展也有助于降低风能和其他形式可再生能源的成本。快速生产风能容量的最大障碍之一是制造风力涡轮机转子叶片的成本和交付时间。风力叶片的规模不断扩大意味着与材料、劳动力和工具相关的主要制造成本是一个限制因素。有人建议，制造一个模具，作为内部结构的叶片将目标通过实现自动化和减少材料的使用，消除了需要昂贵的钢背复合材料molds.Additive制造（AM）是一个使能技术，这是至关重要的，在未来生产大规模的结构，这些成本的来源。它的主要功能是更有效地利用材料和劳动分工的风力叶片生产。AM使拓扑优化（TO）用于大型结构的设计。TO提供了一种为特定性能需求设计结构的方法。AM允许创建这些已定制的结构，使这两种技术成为生产旨在满足特定需求的结构的理想匹配。TO和AM的结合可以创造出高效、浪费最少、生产速度最高的结构。在风力叶片设计中使用拓扑优化有两个主要挑战。首先，叶片的气动弹性响应是结构设计中的一个重要因素，因为它可以通过优化刚度和调谐固有频率来提高叶片从风中捕获能量和减轻负载的能力。拓扑优化不容易与气动弹性求解器兼容，并且由于这一困难，将气动弹性设计与拓扑优化相结合的研究有限。其次，由于弯矩臂的尺寸，复合材料层合板是大型风力涡轮机叶片的关键部件。针对正交各向异性层合板和多种材料的拓扑优化在设计大规模可制造结构时计算量大的问题，提出了一种基于拓扑优化和增材制造的风力涡轮机叶片复合材料层合板结构优化设计方法。该方法涉及多阶段拓扑优化过程;在第一阶段中，基于理想化拓扑优化解决方案设计复合层压结构;在第二阶段中，第一阶段的结果被冻结并用于设计3D打印的重复单元结构，该结构支撑复合层压材料并允许改进的可制造性。该过程的目标是将结构要求的常规知识联合收割机组合以有效使用复合层压结构，同时还能够包括增材制造以支持和改善性能、重量和制造成本。