Weight reduction of an unmanned aerial vehicle pylon fitting by topology optimization and additive manufacturing with electron beam melting

2021-12-01
The operating altitudeof unmanned aerial vehiclescan be affected by many parameters. Lightening the structural parts to achieve targetaltitudeis one of the design efforts. Weight reductioncan beachieved by converting primary and secondary structures from metallic to carbon composite material. In addition, some secondary structures, such as fittings, have to be produced metallic and usually made ofaluminum alloys. In addition to the weightdisadvantage,aluminum alloyshave galvanic incompatibility with carbon composite materials. At this point, additive manufacturing methods offer solutions with a combination oftopology optimization. Complex geometries obtained from topology optimization can beeasilymanufactured by additive manufacturing methods duringweight reduction campaignsof unmanned aerial vehiclessuch as fittings. In this study, the pylon fitting of an unmanned aerial vehicleis lightenedby the topology optimization method using commercial software with an engineering approach. The resulting complex geometry isproduced as Ti-6Al-4V by the Electron Beam Melting additive manufacturing method. As a result of the campaign, a fitting design that is both lightweight and galvanic compatible with carbon composite primary structures has emerged. In this way, an engineering approach has been developed forweight reduction campaigns
Journal of Additive Manufacturing Technologies

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Citation Formats
F. Yilmaz, M. Şahin, and E. Gürses, “Weight reduction of an unmanned aerial vehicle pylon fitting by topology optimization and additive manufacturing with electron beam melting,” Journal of Additive Manufacturing Technologies, vol. 1, no. 2, pp. 1–5, 2021, Accessed: 00, 2022. [Online]. Available: https://journals.infinite-science.de/index.php/jamtech/article/view/553/299.