Synthesis of Design Solutions for High-Pressure Pump Casings

Abstract

Development of modern rocket and space technology is difficult to imagine without the development and implementation of new manufacturing technologies. One such innovation is 3D printing. The development of additive technologies has made it possible to create geometric shapes for parts and assemblies that are practically unlimited in complexity, which was impossible when using traditional manufacturing and processing methods. The use of new forms and designs with the implementation of topology optimization helps to more efficiently and rationally use material, as well as create lightweight and improved designs that meet strength and stability standards, among others.

Topology optimization of structures is a mathematical approach capable of solving a number of engineering tasks. It iteratively solves the problem of rational material distribution in a structure within a limited space, taking into account boundary conditions and acting loads. The method of topology optimization is used at the initial stage of designing structures or modernizing existing ones. The obtained optimal solution is further modified based on technological and functional requirements. This approach significantly saves time at the initial stage of design.

This paper presents the results of implementing the Selective Laser Melting (SLM) technology and topology optimization conducted at FlightControl Propulsion company, using the example of implementing the design of an oxidizer pump inlet for a turbopump unit (TPU) of a liquid rocket engine (LRE).