Topology optimization for the design of a 3D-printed rotating shaft balance

Abstract Rotating shaft balances (RSBs) are devices that used to measure rotor blade forces and moments of wind tunnel models during tests. The design an RSB can be challenging, because it has comply with many sometimes contradicting requirements such as high stiffness strain gauge bridge outputs. manufacturing a conventional consists different subsequent steps, which time consuming, expensive associated risks. Therefore, in this work, the authors investigate if designed by topology optimization manufactured 3D printing. A method was developed objective minimization energy constraints for volume RSB’s midsection, defined stresses at locations measurement axial force torque overhang constraint additive manufacturing. optimal preliminary found translated into final printable highest sensitivity torque, sufficient output in-plane acceptable safety factor on strength combined loads. After adding extra supports required printing, successfully printed metal laser powder bed fusion process, resulting product without external defects. same potentially other balance types, leading reduction total lead costs while increasing freedom.