Topology optimization and finite elemental analysis for an inconel 718 engine mounting bracket manufactured via electron beam melting

In recent years, there is a growing interest in additive manufacturing (AM) technologies for aerospace industries because it offers direct digital manufacturing of highly complex fully functional critical components. Among the all AM techniques, electron beam melting (EBM), a powder bed fusion process, is one of the most promising methods because of its freedom production of complex geometries as well as improved mechanical properties. EBM can be used to manufacture functional critical components in aerospace applications such as brackets for serving as engine mounts. For brackets or engine mounts, it is critical to damper vibration and also support the weight of the engine during service. Therefore, the mechanical properties of the brackets are very critical as well as the weight reductions without sacrificing the dynamic mechanical properties. In this work, topology optimization methods are used to optimize geometry of an engine bracket for its lightweight and highperformance. The topology optimization of the engine bracket was done using ANSYS and OptiStruct software. Reduction in the weight of the engine mounting taking into account of design and material layout was determined and compared between two software. In addition, the effect of different loading conditions on the topology optimization of the EBM-built Inconel 718 bracket was studied.