增材制造损坏替换件拓扑优化设计方法

应急保障和战时抢修是增材制造技术发展的重要方向之一，也给面向增材制造的结构优化设计提出了新的挑战。为了实现异种材料原位替换件的构型设计，提出增材制造损坏替换件拓扑优化设计方法，并以机用散热风扇为例开展应用研究。通过分析散热风扇服役环境和战时抢修需求，在变密度方法框架下建立结构总重量和转动惯量控制在原件数据附近小范围以内、以结构整体柔顺度最小化为目标的拓扑优化问题列式，并完成灵敏度分析公式推导。从拓扑优化结果及其重构模型的仿真数据可知：散热风扇替换件拓扑优化结果收敛性好、满足所有设计要求，重构方案满足增材制造工艺性要求，验证了本文设计方法的有效性。

Topology optimization for designing replacement of damaged part manufactured by additive manufacturing

This paper proposes a novel application of topology optimization method for designing replacement of the damaged part for emergency support and rush-repair based on additive manufacturing. The cooling fan of an airplane is investigated as an example. Based on the analysis of the service environment and rush-repair requirement, the replacement part of the damaged cooling fan should be designed for additive manufacturing using alternative to the materials of the original part. Meanwhile, the weight and the moment of inertia of the replacement part should be kept as equal as possible to those of the original part. Accordingly， the topology optimization formulation is established to minimize the overall structural compliance under the interval constraints of the weight and the moment of inertia of the whole structure. Sensitivity analysis is carried out consider the design-dependent effects of the centrifugal forces. According to the topology optimization result and the analysis data of the re-modelled structure, the obtained replacement part meets the requirements of performances and additive manufacturing process. Finally, the replacement part is successfully printed using Selective Laser Melting, demonstrating the proposed method is effective for additive manufacturing.