Journal of Additive Manufacturing Technologies
Vol 1 No 3 (2021): J AM Tech
https://doi.org/10.18416/JAMTECH.2111583

Articles, ID 583

Topology optimization and manufacturing of engine bracket using electron beam melting

Main Article Content

Murat Işık (Integrated Manufacturing Technologies Research and Application Center, Sabanci University, Orhanli-Tuzla, 34956 Istanbul, Turkey), Erdal Kisa  , Mehmet Yildiz  (Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli-Tuzla, 34956 Istanbul, Turkey), Baris Pehlivanogullari (Tusas Engine Industries Inc., 26003, Eskisehir, Turkey), Akin Orhangul  (Tusas Engine Industries Inc., 26003, Eskisehir, Turkey), Guray Akbulut  (Tusas Engine Industries Inc., 26003, Eskisehir, Turkey), Bahattin Koc  (Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli-Tuzla, 34956 Istanbul, Turkey)

Abstract

Nickel-based alloys are widely used for aerospace applications since they exhibit tremendous mechanical strength under extreme conditions. Additive manufacturing (AM), especially electron beam melting (EBM), technology is of interest due to its potential of direct digital manufacturing of highly complex fully functional light-weight critical components such as engine brackets. Most critical tasks of the brackets in their use, are to damper the vibration and support the engine weight. Consequently, it is desired simultaneously to reduce weight and maintaining good mechanical properties where the topology optimization is the right tool.  In this study, the reference and weight-reduced brackets are fabricated via EBM method, and then followed by subjecting to the hot isostatic pressing (HIP) procedure. The engine bracket is weight reduced with a value of 32.08% utilizing a developed finite element analyses (FEA) based topology optimization. Furthermore, the effect of different loading conditions on the topology optimization of the EBM-built Inconel 718 bracket is studied. The mechanical property values for the FEA are obtained based on experimental data. The reference and topologically optimized brackets are subjected to the tensile tests using a tailor-made fixture and the area under the ‘Load vs. Tensile Extension’ curves are estimated to obtain average energy values using software where a 16.3% energy increase is witnessed.

Article Details

How to Cite

Işık, M., Kisa , E. ., Yildiz , M. ., Pehlivanogullari, B. ., Orhangul , A. ., Akbulut , G. ., & Koc , B. (2021). Topology optimization and manufacturing of engine bracket using electron beam melting. Journal of Additive Manufacturing Technologies, 1(3), 583. https://doi.org/10.18416/JAMTECH.2111583