Abstract In high-speed vehicles, rudders often endure both aerodynamic pressure and thermal loads. The innovative design of rudders is of great importance for the performance of the whole vehicle. In this work, thermo-elastic topology optimization is adopted to design a typical all-movable rudder structure. The compliance of the rudder skin is considered to be a new objective and the moment of inertia of the rudder is constrained during optimization to ensure its fast response to instructions of the control system. Then sensitivity analysis of the structural compliance and the moment of inertia is carried out. Optimization results show that thermal load has a great effect on the optimized configuration and minimizing the compliance of the rudder skin gives much better design than minimizing the global compliance. Subsequently, an engineering-oriented post-processing is conducted to make the optimized design suitable for additive manufacturing. An appropriate printing direction is selected based on the layout of the optimized ribs and certain ribs are reshaped with fillets to make the rudder free of internal support structures. Besides, according to a secondary topology optimization of the ribs and the stress distribution, a set of powder-discharge holes are properly opened on the ribs so that all cavities within the rudder are connected and the metal powder inside the rudder can be discharged with little effort after manufacturing. Finally, the optimized design is successfully printed using Selective Laser Melting, demonstrating the proposed post-processing is effective for additive manufacturing.

中文翻译：

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通过热弹性拓扑优化设计并通过增材制造制造的全动舵

摘要 在高速车辆中，方向舵通常同时承受气动压力和热载荷。方向舵的创新设计对整车的性能至关重要。在这项工作中，采用热弹性拓扑优化设计了一个典型的全动舵结构。舵皮的柔顺性被认为是一个新的目标，在优化过程中对舵的惯性矩进行约束，以确保其对控制系统指令的快速响应。然后进行结构柔量和转动惯量的敏感性分析。优化结果表明，热载荷对优化配置有很大影响，与最小化整体柔度相比，最小化舵皮的柔度可提供更好的设计。随后，进行面向工程的后处理，使优化设计适合增材制造。根据优化后的加强筋的布局选择合适的印刷方向，并用圆角重新塑造某些加强筋的形状，使舵摆脱内部支撑结构。此外，根据加强筋的二次拓扑优化和应力分布，在加强筋上适当开设了一组排粉孔，使舵内所有腔体连通，舵内金属粉末几乎可以排出。制造后的努力。最后，使用选择性激光熔化成功打印了优化设计，证明了所提议的后处理对于增材制造是有效的。