An aerospace bracket designed by thermo-elastic topology optimization and manufactured by additive manufacturing

Combination of topology optimization and additive manufacturing technologies provides an effective approach for the development of light-weight and high-performance structures. A heavy-loaded aerospace bracket is designed by topology optimization and manufactured by additive manufacturing technology in this work. Considering both mechanical forces and temperature loads, a formulation of thermo-elastic topology optimization is firstly proposed and the sensitivity analysis is derived in detail. Then the procedure of numerical optimization design is presented and the final design is additively manufactured using Selective Laser Melting (SLM). The mass of the aerospace bracket is reduced by over 18%, benefiting from topology and size optimization, and the three constraints are satisfied as well in the final design. This work indicates that the integration of thermo-elastic topology optimization and additive manufacturing technologies can be a rather powerful tool kit for the design of structures under thermal-mechanical loading.     

激光金属沉积技术研究现状与应用进展

增材制造是融合材料科学、机械自动化及信息技术的先进制造技术,在近30年的发展中,发挥着越来越重要的作用。激光金属沉积(Laser metal deposition,LMD)是基于定向能量沉积(Directed energy deposition,DED)的一种增材制造技术,在近年来受到广泛关注和研究。阐述了LMD技术的基本工作原理及系统组成,重点介绍LMD技术国内外研究进展及应用现状,列举了一些基于LMD的工艺技术开发及装备研发制造,指出了LMD技术在成形效率和成形精度、工艺稳定性及性能一致性等方面的不足。最后,总结了LMD技术未来的5个发展趋势:材料体系集约化、工艺参数系统化、成形过程高效化、设备集成智能化和应用领域广泛化。     

民用飞机气动外形数值优化设计面临的挑战与展望

系统回顾了气动外形优化的主要环节，对优化体系中学科分析、参数化建模、网格重构技术、敏度分析、优化算法、代理模型、目标函数/约束处理等各个环节的进展，及气动综合优化面临的挑战、基础科学问题进行了总结。结合课题组在优化体系建设上开展的研究工作，针对民用飞机气动外形综合设计的需求，提炼了工程型号对优化体系构建的具体要求。并对今后的研究工作以及未来发展方向进行了展望与建议。通过文章系统整理论述，希望能够为气动数值优化设计研究人员提供一些有意义的建议和参考，促进设计空气动力学、以及多学科优化技术的发展。     

Design and application of solar sailing: A review on key technologies

Solar sail technology has been proposed and developed for space explorations with advantages of low launch cost, no-propellant consumption, and continuous thrust, which has great potentials in earth polar detection, interstellar explorations and etc. The development of solar sail has made significant progress in structural design, manufacturing, materials, orbit transfer, and stability control in the past few decades, which makes meaningful contributions to astronomy, physics, and aerospace science. Technological breakthroughs of Solar Radiation Pressure (SRP) propulsion and interstellar transfer have been achieved in current solar sail missions. However, there are still many challenges and problems need to be solved. This paper attempts to summarize the research schemes and potential applications of solar sailing in space missions from the viewpoint of key technologies, so as to provide an overall perspective for researchers in this field. Analyses of the key technologies of solar sailing system design are provided. Finally, challenges and prospective development of solar sailing are discussed.     

面向控制的高超声速飞行器总体优化设计方法

从前期高超声速飞行器基础理论以及关键技术的研究到现今的飞行试验可以看出,高超声速飞行器在总体设计阶段过晚考虑飞行器动力学特性和控制性能会给后期控制系统设计带来极大的困难。在对两类高超声速飞行器试飞与控制相关问题分析的基础上,提出了面向控制的高超声速飞行器总体优化设计方法,给出了面向控制的总体优化设计研究方法、思路和模块框架。     

金属增材制造技术应用于军用飞机维修保障浅析

金属增材制造技术的发展为军用飞机维修保障提供了一条数字化、定制化、高性能、短周期的技术新途径,可提升军用飞机维修保障的技术水平和能力。本文综述了军用飞机维修保障的国内外现状,指出了金属增材制造技术的应用优势,介绍了军用飞机零件的典型损伤形式、不同增材制造工艺的适用性及修复工艺选取方案,分析了所涉及的逆向建模、结构优化、智能机器人等关键技术,详述了目前存在的技术成熟度与可靠性不高、修复原则不明确、标准规范不统一等主要问题及解决措施,指出了增材制造技术在军用飞机维修保障领域未来的发展方向和趋势,并给出了具体的应用建议。     

Collaborative optimization design of process parameter and structural topology for laser additive manufacturing

High-resolution laser additive manufacturing (LAM) significantly releases design freedom, promoting the development of topology optimization (TO) and advancing structural design methods. In order to fully take advantage of voxelated forming methods and establish the quantitative relationship between the mechanical properties of printing components and multiple process factors (laser- and process- parameters), the concurrent optimization design method based on LAM should cover the process-performance relationship. This study proposes a novel artificial intelligence-facilitated TO method for LAM to concurrently design microscale material property and macroscale structural topology of 3D components by adopting heuristic and gradient-based algorithms. The process–structure–property relationship of selective laser sintering is established by the back propagation neural network, and it is integrated into the TO algorithm for providing a systematic design scheme of structural topology and process parameter. Compared with the classical optimization method, numerical examples show that this method is able to improve the mechanical performance of the macrostructure significantly. In addition, the collaborative design method is able to be widely applied for complex functional part design and optimization, as well as case studies on artificial intelligence-facilitated product evaluation.     

面向增材制造的拓扑优化技术发展现状与未来

增材制造技术通过材料逐层打印制备结构,为复杂构件制造提供了新的成形方式。拓扑优化因不依赖于初始构型的选择,可设计出传统理念难以获得的创新构型,已成为航空航天和高端装备领域高性能、轻量化结构设计的重要手段。拓扑优化与增材制造有机融合,充分发挥各自优势和潜力,在现代制造业中展现出广阔应用前景。回顾了近年来关于增材制造与拓扑优化技术融合研究的主要内容和应用成果,包括以材料结构一体化为核心的多尺度/多层级结构优化设计、以设计制造一体化为核心的考虑增材制造工艺约束的优化方法等。同时,也分析了未来研究工作中存在的问题与挑战,如点阵结构性能表征及其尺度关联效应、增材制造材料成形各向异性、功能梯度材料与结构、增材制造材料与结构疲劳特性等对设计方法和成形工艺带来的挑战,为未来相关研究工作和航空航天应用提供参考。     

通用飞行器气动优化设计数字化集成平台——DIPasda

未来航空工业的发展，需要解决多学科综合设计的关键问题，为新型高性能飞行器的设计提供有力的设计方法和设计工具。DIPasda作为复杂外形设计的通用飞行器多学科优化设计平台，研制目的主要是提供一套新型通用、鲁棒、高效的优化设计架构，应用于通用飞行器工业设计环境，改善传统设计耗时低效的状况，提高新型飞行器设计的效率和精度。DIPasda平台系统包含了优化设计过程中所需用到的各类方法，主要包括数值优化算法、几何模型参数化方法、代理模型方法、高精度的学科分析工具等。通过详细介绍平台的系统架构、主要的功能模块、伴随优化设计和多目标优化设计流程，展现了DIPasda平台系统架构设计的灵活性和功能模块的完备性。最后通过优化算例展示了系统的综合优化设计能力。     

Variable-fidelity optimization with design space reduction

Advanced engineering systems, like aircraft, are defined by tens or even hundreds of design variables. Building an accurate surrogate model for use in such high-dimensional optimization problems is a difficult task owing to the curse of dimensionality. This paper presents a new algorithm to reduce the size of a design space to a smaller region of interest allowing a more accurate surrogate model to be generated. The framework requires a set of models of different physical or numerical fidelities. The low-fidelity (LF) model provides physics-based approximation of the high-fidelity (HF) model at a fraction of the computational cost. It is also instrumental in identifying the small region of interest in the design space that encloses the high-fidelity optimum. A surrogate model is then constructed to match the low-fidelity model to the high-fidelity model in the identified region of interest. The optimization process is managed by an update strategy to prevent convergence to false optima. The algorithm is applied on mathematical problems and a two-dimen-sional aerodynamic shape optimization problem in a variable-fidelity context. Results obtained are in excellent agreement with high-fidelity results, even with lower-fidelity flow solvers, while showing up to 39% time savings.     

高超声速飞行器多目标气动优化设计

随着高超声速飞行器的发展,其外形优化受到了广泛关注。应用一种新型的改进多目标布谷鸟优化搜索算法(IMOCS),采用修正的牛顿法与面元法相结合来获得高超声速飞行器的气动性能,采用自由变形参数化方法(FFD)来进行外形的参数化,以最大化容积率和升阻比为设计目标,开展了高超声速滑翔飞行器的多目标气动外形优化设计,获得了综合容积率及升阻比性能更高的气动外形,验证了方法的有效性。最后,将IMOCS算法和当前主流的多目标优化算法NSGA-Ⅱ进行了对比,结果表明,IMOCS算法的效果明显优于NSGA-Ⅱ。     

Neural Network aided PMSM multi-objective design and optimization for more-electric aircraft applications

This study uses the Neural Network (NN) technique to optimize design of surface-mounted Permanent Magnet Synchronous Motors (PMSMs) for More-Electric Aircraft (MEA) applications. The key role of NN is to provide dedicated correction factors for the analytical PMSM mass and loss estimation within the entire design space. Based on that, a globally optimal design can be quickly obtained. Matching the analytical estimation with Finite-Element Analysis (FEA) is the main research target of training the NN. Conventional analytical formulae serve as the basis of this study, but they are prone to loss accuracy (especially for a large design space) due to their assumptions and simplifications. With the help of the trained NNs, the analytical motor model can give an estimation as accurate as the FEA but with super less time during the optimization process. The Average Correction Factor (ACF) approach is regarded as the comparison method to demonstrate the excellent performance of the proposed NN model. Furthermore, a NN aided three-stage-seven-step optimization methodology is proposed. Finally, a Pole-10-Slot-12 PMSM case study is given to demonstrate the feasibility and gain of the NN aided multi-objective optimization approach. In this case, the NN aided analytical model can generate one motor design in 0.04 s while it takes more than 1 min for the used FEA model.     

拓扑优化与增材制造结合:一种设计与制造一体化方法

被誉为"第三次工业革命"的增材制造技术通过材料层层累加的方式实现结构的制备,这种独特的制造方式实现了高度复杂结构的自由"生长"成形,极大地拓宽了设计"空间",为新型结构及材料的制备提供了强大的工具。制造工艺的飞速发展往往需要设计技术的快速跟进,拓扑优化方法因其不依赖初始构型及工程师经验,可获得完全意想不到的创新构型,已成为结构创新设计的重要工具。因此,将拓扑优化(先进设计技术)与增材制造(先进制造技术)融合,发展面向增材制造的创新设计技术具有广阔的前景。从面向增材制造的优质结构构型设计以及考虑增材制造工艺约束的拓扑优化设计方法两个方面,介绍了现阶段基于拓扑优化方法所建立的结构创新设计理论,并指出未来研究的趋势。     

基于伴随理论的大型客机气动优化设计研究进展

大型民用客机的气动设计具有巡航马赫数高、部件间流动干扰复杂、外形精细化修形难度大等特点，完全依靠人工试凑法进行气动设计工作量巨大。基于高可信度数值模拟的优化设计技术可以对该类问题进行自动寻优设计，给设计师提供有力参考，因此在大型民用客机气动设计中发挥着越来越显著的作用。首先，以大型民用客机为背景，总结了民机气动设计中的关键科学问题，指出了梯度优化设计方法在民用客机不同优化设计问题中的适用性，并进一步对梯度求解中的伴随方法理论进行了详细介绍。然后，分析了基于伴随理论的气动优化设计方法以及气动结构多学科优化设计方法在民用客机设计中的研究进展，其中气动优化设计方面着重突出了复杂全机多部件气动外形优化设计方法以及飞机/发动机一体化优化设计方法。最后，对基于伴随理论的气动优化设计方法在大型民机中的应用进展进行了提炼，对未来发展趋势进行了展望与建议。     

基于响应面法的机翼气动/结构一体化优化设计研究

基于响应面法进行了机翼气动/结构一体化优化设计研究,流动控制方程为三维欧拉方程,采用有限体积法进行数值求解,应力和结构变形采用有限元方法计算,静气动弹性分析采用强耦合迭代方式,响应面模型采用二次多项式来构造。以跨音速M6机翼为初始机翼,进行了多目标、多约束情形下的气动/结构综合优化设计,优化后所得到的新机翼具有更佳的气动/结构综合性能,升阻比增加了9.25%,而重量减轻了4.84%;响应面模型精度满足设计要求,拟合误差均不超过1%;这说明本文所发展气动/结构综合优化设计方法是成功且有效的,具有广泛的应用前景。     

Filters for manufacturability in design optimization of variable stiffness composites

In the design optimization of variable stiffness composites, manufacturing constraints imposed by the automated fiber placement technology must be considered. In the present paper, two filters are proposed to address this issue, and they are incorporated into the Shepard interpolation-based design optimization framework developed in our previous studies. The fiber angle arrangement of a composite is represented by a continuous function that interpolates fiber angles at scattered design points. Two filters are appointed for each design point to deal with two typical manufacturing constraints, i.e., fiber curvature and gap/overlap. At each design point, the sensitivity is first filtered in a rectangular region around this point, and by this means the fiber curvature is controlled; then in another rectangular region around this design point, the filtered sensitivities are averaged, and the result is used to update the corresponding design variable. Several numerical examples are investigated, and the results show that the proposed method is effective.     

Review of uncertainty-based multidisciplinary design optimization methods for aerospace vehicles

This paper presents a comprehensive review of Uncertainty-Based Multidisciplinary Design Optimization (UMDO) theory and the state of the art in UMDO methods for aerospace vehicles. UMDO has been widely acknowledged as an advanced methodology to address competing objectives of aerospace vehicle design, such as performance, cost, reliability and robustness. However the major challenges of UMDO, namely the computational complexity and organizational complexity caused by both time-consuming disciplinary analysis models and UMDO algorithms, still greatly hamper its application in aerospace engineering. In recent years there is a surge of research in this field aiming at solving these problems. The purpose of this paper is to review these existing approaches systematically, highlight research challenges and opportunities, and help guide future efforts. Firstly, the UMDO theory preliminaries are introduced to clarify the basic UMDO concepts and mathematical formulations, as well as provide a panoramic view of the general UMDO solving process. Then following the UMDO solving process, research progress of each key step is separately surveyed and discussed, specifically including uncertainty modeling, uncertainty propagation and analysis, optimization under uncertainty, and UMDO procedure. Finally some conclusions are given, and future research trends and prospects are discussed.     

飞机战伤抢修评估与设计方法综述

飞机战伤抢修（ABDR）是提高飞机生存力与作战能力的重要手段之一，开展战伤抢修技术研究覆盖飞机全寿命阶段。回顾了战伤抢修研究的历史和现状，分别从战伤评估、战伤抢修设计、战场维修与保障等3方面总结了战伤抢修体系要点，重点综述了战伤抢修预评估技术、战伤现场评估技术、战伤抢修设计准则与原则、战伤抢修设计与评价方法、战场快速维修技术、战场保障方法等方面的理论与研究进展。在此基础上，针对未来体系对抗与智能化作战环境，结合目前战伤抢修需求，提出了包括先进材料结构飞机战伤抢修技术、直升机战伤抢修技术、飞机战伤评估智能技术等战伤抢修技术研究需要关注和解决的问题。     

Kriging模型及代理优化算法研究进展

代理模型方法由于能显著提高工程优化设计问题的效率,在航空航天及其他领域得到了广泛重视,并逐渐发展成为一类优化算法,本文称其为代理优化（SBO）算法。在现有的代理模型方法中,如多项式响应面、径向基函数、神经网络、支持向量回归、多变量插值/回归、多项式混沌展开等,源于地质统计学的Kriging模型具有代表性,是一种非常具有应用潜力的代理模型方法。以飞行器设计领域的优化问题为背景,介绍了Kriging代理模型及应用于优化设计的理论和算法的最新研究进展。首先,概述了Kriging模型的基本理论和算法,并讨论了影响Kriging模型鲁棒性和效率的几个关键性问题。其次,回顾了Kriging模型理论和算法研究的3个最新研究进展,包括梯度增强型Kriging、CoKriging和分层Kriging模型。而后,分析提炼了基于Kriging模型的代理优化算法的优化机制和优化框架,给出了“优化加点准则”和“子优化”的概念,并介绍了目前常用的几种优化加点准则及其相应子优化问题的求解与约束处理;同时,还介绍了最新提出的局部EI加点准则以及代理优化的终止条件。最后,介绍了代理优化在标准测试函数算例验证、飞行器气动与多学科优化设计典型算例确认方面的研究进展,并对当前存在的一些关键科学问题以及未来研究方向进行了讨论。     

A new efficient technology of aerodynamic design based on CFD driven optimization

This paper describes a new technology of aerodynamic design based on CFD driven constrained optimization to minimum drag. Within an aircraft development project we focus on the aerodynamic design of wings and show how the design process has been advanced with the new capabilities achieved through the use of the recently developed in-house optimization tool OPTIMAS. The optimization method of the present work is based on the use of Genetic Algorithms and accurate full Navier–Stokes drag prediction. The results include a variety of optimization cases for aerodynamic design of transport-type aircrafts.