关键词: 拓扑优化, 增材制造, 各向异性, Tsai-Wu准则, 航空发动机盘类件, 轻量化

Abstract: Disk-type components are widely used in aero-engines, and their performance optimization is a key factor in enhancing overall engine performance. Additive manufacturing technology significantly expands the design space for such structures due to its high degree of processing freedom. However, its inherent layer-by-layer deposition characteristic results in significant anisotropy along the printing direction, posing challenges for structural design. To address this, a topology optimization method for aero-engine disk-type components that accounts for additive manufacturing-induced anisotropy is proposed. First, considering the features of disk-type components, an anisotropic material model suitable for axisymmetric structures is established, providing a theoretical foundation for material property interpolation and structural optimization. Second, the numerical discretization of the Tsai-Wu strength criterion for anisotropic axisymmetric structures is implemented, which can effectively predict the anisotropic strength distribution of printed parts and reflect the tensile-compressive asymmetry along the printing direction. Next, a topology optimization model is constructed with the objective of minimizing mass and the constraint of anisotropic strength. The sensitivities of the objective function and constraints are derived based on the adjoint method. Finally, the effectiveness of the proposed method is validated through three case studies: a symmetric compressor disk, an asymmetric turbine disk, and a turbine rear cooling plate. Compared with traditional designs based on the von Mises criterion, the proposed method achieves a mass reduction of over 20% while ensuring structural safety, significantly improving lightweight performance and design reliability. This provides an effective approach for the safe and lightweight design of additively manufactured axisymmetric structures.

Key words: topology optimization, additive manufacturing, anisotropy, Tsai-Wu criterion, aero-engine disks, lightweight design