Algorithm for constructing a 3D model of a three-layer rotation shell with cone-shaped cells of the filler and variable shape forming

Design, construction and manufacturing of flying vehicles


Zotov A. A.*, Kolpakov A. M.**, Volkov A. V.***




Assigned the task of designing and manufacturing three – layer rotation shells with filler from conical cells and variable forming. The long-term operating experience of various technical objects made with the use of three-layer bags has shown their high efficiency due to the fact that, with low weight, they have high specific strength and rigidity. Their disadvantages include: low impact strength, complexity with the removal of condensate, low shear strength, the complexity of manufacturing. Traditional techniques for combining filler with bearing layers in the form of gluing or spot welding have low reliability, it is difficult to control the quality of joints. New technologies for manufacturing these structures from high-strength reinforced composite materials (glass, carbon plastic) and wide possibilities for optimizing their geometrical parameters make it possible to achieve higher strength characteristics of the aggregate for transverse compression, longitudinal shear and bending. Nevertheless, the problems of condensate removal, reducing the complexity of manufacturing, ensuring the reliability of the connection of the aggregate with the support layers, as well as the complexity of the construction of structures with variable geometric configuration make us look for new solutions.

This one shows the possibilities of using three-layer structures with a filler in the form of staggered cone-shaped cells made using 3D printing, which, in our opinion, largely avoid the above disadvantages.

The proposed regular structure and form of the elements of the aggregate makes it possible to carry out in one operation the construction of a complex configuration, providing ways to remove condensate, reliability of connection with the outer layers, having high thermal and sound insulating properties. A mathematical model has been developed and a demonstration model manufacturing algorithm has been implemented. CAD – model built according to the results of the calculation of the parameters of the shell and its placeholder.

Samples are made by FDM-technology. The presented designs are offered for use in aviation, aerospace, automobile, engineering, as well as in the production of refrigeration and cryogenic devices.


three - layer rotation shell, variable forming, filler structure and design, 3D printing, additive technology, demo models


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