Structural Integrity Evaluation of SLM Ti-6Al-4V Components with Optimized Geometrical Features
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Keywords:
Ti6Al4V Alloys, Mechanical Properties, Selective Laser Melting, Additive Manufacturing, OptimizationAbstract
This study investigates the integration of topology optimization (TO) and additive
manufacturing (AM) for lightweighting aerospace components, focusing on a structural bracket fabricated
from Ti-6Al-4V (Ti64) via selective laser melting (SLM). The primary objective was to analyze the
component's structural response under static loading and to evaluate the influence of load magnitude on
topology optimization outcomes for 30% and 50% mass reduction targets. Finite element analysis (FEA)
was conducted using assigned SLM Ti6Al4V material properties, applying static loads of 20 kN and 40
kN. The simulation results demonstrate that the bracket operates well within its linear elastic range,
exhibiting a high factor of safety; the maximum observed elastic stress (approximately 81 MPa at 20 kN)
remained significantly below the material's typical tensile strength (800-1200 MPa). Critically, the
topology optimization algorithm produced nearly identical optimized geometries for both 30% and 50%
mass reduction targets, irrespective of whether the 20 kN or 40 kN load was applied. This main finding
indicates that for this linear system, the optimal material layout is conducted by the mass reduction target
and initial geometry, not the load's magnitude. This conclusion supports the use of SLM Ti6Al4V and TO
for creating strong, lightweight structures and suggests a potential to update the design process by
reducing redundant optimization analyses within a linear loading range.
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