Topology Optimization Design of Aero-Engine Auxiliary Bracket under Additive Manufacturing Constraints

Abstract

Aiming to address the issues of redundancy and insufficient lightweight design in traditional engine auxiliary brackets, this study integrates the characteristics of additive manufacturing (AM) technology to conduct a lightweight design for engine auxiliary brackets under AM constraints. With the objective of maximizing bracket stiffness, material distribution optimization was performed on the initial bracket while comprehensively considering manufacturing constraints. Based on the topology optimization results, a novel AM-compliant engine auxiliary bracket structure was developed through geometric reconstruction and local feature reinforcement. Finite element analysis (FEA) was employed to compare the maximum displacement, stress distribution, and mass of the structure before and after optimization. The results demonstrate that the optimized bracket achieved a 25.68%↓ reduction in mass, 68.53%↓ decrease in maximum displacement, and 53.20%↓ reduction in maximum stress. This research validates the effectiveness of the synergistic design combining topology optimization and additive manufacturing in lightweighting complex load-bearing components, providing theoretical foundations and engineering references for innovative designs of similar bracket structures.