Abstract

Topology optimization is a technique widely used in making a design to have a lighter structure providing the same functionality. With topology optimization, it is possible to design a product much lighter with the same strength values. However, structures having a complicated geometric design cannot be produced by conventional manufacturing methods. To eliminate this limitation, additive manufacturing methods, which are widely used in today’s technology, are used in producing the structures with complicated geometric designs. These structures that prosses a complicated design can be produced with only one processing stage in a short period of time. It is aimed to produce the required product in aviation industry quickly, cheaply, and lightly. In this research, it is aimed to produce a Ø32mm and 2mm wall thick AMS 5566 steel tube to be used in the aviation industry by using the additive manufacturing method in the design of the form control tool by using topology optimization. Thus, it is made possible to produce the form control tool quicker, cheaper, and lighter [1]. With the FDM (Fused Deposition Modelling) method, one of the additive manufacturing methods, the form control set is produced with 60% occupancy and 3 rows on the front of the walls. Polylactic Acid (PLA) polymer is used as the production material. The controls that this polymer used was produced within the desired tolerance values after production were also carried out by laser scanning method. According to the results of measurement, the maximum manufacturing mistakes of PLA material are determined as 0,517mm. As a result of the topology optimization, additive manufacturing, and measurement outcomes, it has been decided to use the form control tool in the controls of a steel tube to be used in the aviation industry.

Keywords: Topology optimization; 3D printer; Check form; FDM; Tool