超声速火箭橇支撑结构轻量化设计与性能分析

LIGHTWEIGHT DESIGN AND PERFORMANCE ANALYSIS OF SUPERSONIC ROCKET SLED SUPPORT STRUCTURES

  • 摘要: 超声速火箭橇是航空航天装备性能验证的关键地面试验平台,其下部支撑结构在高速重载及振动服役背景下需同时满足轻量化与高精度测试要求,导致减重需求与刚度、强度要求之间形成严重制约。针对轻量化与结构承载性能难以兼顾的多性能权衡问题,本文构建了一种基于多软件联合仿真与拓扑优化的分阶段结构优化流程。首先在MATLAB中对多种基础构型进行数值预选,确定等腰梯形为最优基础构型;随后利用ANSYS开展参数灵敏度分析,确定40°~48.39°为候选倾角区间;进一步对代表性候选倾角开展初步拓扑优化与力学响应比较,最终确定45°作为后续精细化优化的基础倾角;在此基础上,在Altair Inspire中以体积分数≤30%为约束、刚度最大化为目标开展拓扑优化,进而提出“中字型+X型”复合肋板方案;最后通过ANSYS静力学分析与模态分析,对优化结构的静力承载性能及低阶动力学特性进行评价。优化后结构质量由2.9907×105 kg降低至1.5521×105 kg,减重约48.1%;受材料去除及结构重构影响,最大变形由1.761 mm增加至3.734 mm,最大等效应力由13.53 MPa增加至48.97 MPa,但最大等效应力仍远低于钛合金930 MPa的屈服强度,结构仍保持较大的静强度安全裕度。模态分析表明,优化前结构前6阶固有频率为48.752~101.850 Hz,优化后为36.603~60.996 Hz,说明轻量化重构对结构低阶动力学特性产生了明显影响。该方案实现了从理论拓扑构型到可制造方案的转化,在实现结构轻量化的同时保持了相应的静力承载能力,并明确了优化后结构的低阶模态特性,具有重要的工程应用价值。

     

    Abstract: As a critical ground-testing platform for aerospace equipment performance verification, the supersonic rocket sled requires its lower support structure to meet the requirements of lightweight design and high-precision testing under high-speed, heavy-load, and vibration service conditions, resulting in a pronounced trade-off between weight reduction and structural stiffness and strength. To address this multi-performance trade-off, this study develops a staged structural optimization workflow based on integrated multi-software simulation and topology optimization. First, several basic structural configurations are numerically pre-screened in MATLAB, and the isosceles trapezoidal configuration is selected as the preferred base configuration. Subsequently, parameter sensitivity analysis is carried out in ANSYS to identify a candidate inclination-angle range of 40°~48.39°. Representative configurations within this range are then subjected to preliminary topology optimization and mechanical response comparison, based on which 45° is selected as the base inclination angle for subsequent refined optimization. On this basis, topology optimization is performed in Altair Inspire with stiffness maximization as the objective and a design-domain volume fraction upper limit of 30%. The resulting material distribution is then interpreted to guide the engineering reconstruction of a manufacturable composite rib structure featuring a central web and X-shaped ribs. Finally, static structural and modal analyses are conducted in ANSYS to evaluate the static load-bearing performance and low-order dynamic characteristics of the optimized structure. After optimization, the structural mass is reduced from 2.9907×105 kg to 1.5521×105 kg, corresponding to a weight reduction of approximately 48.1%. Due to material removal and structural reconstruction, the maximum deformation increases from 1.761 mm to 3.734 mm, while the maximum von Mises stress increases from 13.53 MPa to 48.97 MPa. Nevertheless, the maximum stress remains far below the titanium-alloy yield strength of 930 MPa, indicating a considerable static strength margin. Modal analysis shows that the first six natural frequencies change from 48.752~101.850 Hz before optimization to 36.603~60.996 Hz after optimization, indicating that lightweight structural reconstruction has a significant effect on the low-order dynamic characteristics of the structure. The proposed workflow realizes the transformation from a theoretical topology-optimization result to a manufacturable structural design, achieving substantial structural lightweighting while maintaining adequate static load-bearing capacity and characterizing the low-order modal characteristics of the optimized structure, thereby providing an engineering reference for the design of supersonic rocket-sled support structures.

     

/

返回文章
返回