Lightweight design and optimization of pipe connection flanges based on wire arc additive manufacturing

Focusing on the problems of material waste, low production efficiency, poor design flexibility and high cost existing in the traditional flange design by conventional casting and machining processes, a flange design method based on wire arc additive manufacturing (WAAM) was first proposed. A parametric finite element model of the pipe connection flange was established, and the stress and deformation of the flange were simulated and analyzed, using ANSYS. It reveals the weak areas in terms of strength and stiffness of the connecting flange. Then, a sensitivity analysis was conducted on the design parameters of the flange structure. High-sensitivity structural parameters were selected as the optimization design variables. With the minimum volume and weight as the objective functions and the strength and stiffness as the constraint conditions, a robust optimization design model for the pipe connection flange was established. The optimal structural design parameters were obtained by using the orthogonal array test method. The automatic modeling, stress simulation analysis, and lightweight design of the flange structure have been achieved. The new design method proposed in this paper can significantly reduce the design time, material consumption and production cost of flanges, while improving the reliability and safety of pipe connection flanges.