In hybrid lightweight structures, mass can be decreased while maintaining functionality by allocating materials to areas according to the prevailing stress conditions. This approach is interesting for structural guide vanes with limited design space due to aerodynamic requirements and simultaneous demand for mass savings. In this paper, a methodology is presented, which can be used to quickly assess the potential of a hybrid design for a component, using the example of an engine guide vane.
The prevailing stress state is decisive for the material allocation. While isotropic materials are needed to bear the stresses in complex stress states, orthotropic materials can be used for axial or biaxial stress states. The stress analysis required for this classification is usually carried out by manual evaluation of principal stresses in component.
A methodology for the automated evaluation of numerical simulation results (e.g principal stress) and for the spatially resolved derivation of materials suitable for existing stresses reduces the design effort and significantly increases the quality of the analysis results. First, a methodology for identifying similarly stressed areas is presented. Then, the relationship between stress states and the material selection is considered and rules for material assignment based on stress magnitudes and stress states are established.
The developed methodology is implemented using the example of a structural engine guide vane. The geometry of the guide vane generates complex stress states even in simple loading scenarios, making it very suitable for the application of the methodology. Based on the analysis carried out, the potential of implementing a hybrid design for the guide vane can be easily estimated by identifying sufficiently large areas with the same material allocation.