Lightweight design of a bolt-flange sealing structure based on topology optimization
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Lightweight design of a bolt-flange sealing structure based on topology optimization Jie Wang1 · Jihong Zhu1,2 · Jie Hou1 · Chuang Wang1 · Weihong Zhang1 Received: 2 April 2020 / Revised: 13 June 2020 / Accepted: 7 July 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract To date, sealing structures have been widely used in aerospace vehicles. This paper presents a normalized and systematic procedure realizing lightweight design for a square bolt-flange sealing structure of a rocket engine. To measure the sealing behavior, the contact force on the sealing interface is obtained by a nonlinear analysis of node-to-node contact. The topology optimization is established to achieve sufficient contact forces in the sealing area by acquiring the Kreisselmeier-Steinhauser (KS) function to condense multiple contact force constraints into a global sealing constraint. A three-field projection scheme is also adopted to obtain a clear result and a semi-analytical perturbation scheme is proposed to realize the sensitivity calculation. Then, the square flange cover is optimized by the proposed optimization framework and a lightweight design with a clear load-carrying path is obtained. The optimized design is reconstructed and further optimized in detail. Compared with several traditional designs, it shows better leakproofness under inner liquid pressure, which can be directly fabricated by additive manufacturing and used in the rocket engine. The optimization procedure is proved effective and practical in designing sealing structures for aerospace vehicles. Keywords Sealing · Lightweight design · Topology optimization · Contact force · Flange cover design
1 Introduction Fluid mediums such as fuel and hydraulic fluid play an important role in the aerospace vehicles, where sealing is significant, so that the sealing structures have been widely used. Figure 1 shows a rocket engine with a large number of bolt-flange sealing structures and a typical square flange cover is highlighted. Conventional bolt-flange structure adopts a thick flange, a metal gasket, and multiple bolts. The thick flange can restrain its own deformation Responsible Editor: YoonYoung Kim Electronic supplementary material The online version of this article (https://doi.org/10.1007/s00158-020-02683-4) contains supplementary material, which is available to authorized users. Jihong Zhu
[email protected] 1
State IJR Center of Aerospace Design and Additive Manufacturing, Northwestern Polytechnical University, Xian, Shaanxi 710072, China
2
MIIT Lab of Metal Additive Manufacturing and Innovative Design, Northwestern Polytechnical University, Xian, Shaanxi 710072, China
and the large pretightening forces on the multiple bolts can guarantee the sealing. Apparently, this is not only a cumbersome structure system, but also has some inherent defects. Considering that the load is evenly transmitted in the flange, the leakage easily occurs between two bolts, where the pretightening force effect is minimal. In addition,
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