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Design and Optimization of Thin-Walled Main Support Structure for Space Camera Based on Additive Manufacturing
Jiahao Peng1,2, Shijie Liu1, Dong Wang3
1Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Sciences, Changchun 130033, China.
Micromachines
|February 24, 2024
Summary
This study presents an optimized, large-scale, thin-walled structure for auroral imagers using additive manufacturing. The design achieves high stiffness and lightweight properties, validated by experimental and simulation results.
Area of Science:
- Mechanical Engineering
- Materials Science
- Aerospace Engineering
Background:
- Designing lightweight yet stiff structures is crucial for advanced imaging systems.
- Additive manufacturing offers new possibilities for complex, integrated components.
Purpose of the Study:
- To design and optimize a large-scale, thin-walled primary support structure for a wide-field auroral imager.
- To meet high stiffness and lightweight requirements using additive manufacturing.
Main Methods:
- Integrated thin-walled structure design and material testing.
- Shape optimization using Timoshenko cantilever beam theory and lateral slope angle adjustment.
- Active fitting optimization algorithm for wall thickness refinement.
- Selective Laser Melting (SLM) for manufacturing the primary support.
Main Results:
- A large-scale (538 mm × 400 mm × 384 mm) and lightweight (7.78 kg) primary support structure was successfully manufactured.
- Experimental natural frequency (105.97 Hz) closely matched finite element analysis (FEA) results (approx. 3% error).
Conclusions:
- The developed large-scale, complex, thin-walled structure meets the design requirements for high stiffness and low weight.
- Additive manufacturing, combined with advanced optimization techniques, is a viable solution for producing such specialized components.
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