Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and...
-
Upload
altair-engineering -
Category
Technology
-
view
4.190 -
download
3
Transcript of Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and...
Engineering the Future…
…with Photons
Development
Consulting
Education
Research
Structural Optimization and
Laser Additive Manufacturing
(LAM) in lightweight design:
barriers and chances
Dipl.-Ing. J. Kranz
Prof. Dr.-Ing. C. Emmelmann
Turin, 23. April 2013
EATC 2013
Dipl.-Ing. J. Kranz
2 23.04.2013
LZN Laser Zentrum Nord GmbH and
Institut of Laser and System Technologies (iLAS)
City of Hamburg, Germany
EATC 2013
Dipl.-Ing. J. Kranz
3 23.04.2013
Agenda
1. Laser Additive Manufacturing
2. Current Barriers in Application
3. Chances for Lightweight Design
4. Conclusion
EATC 2013
Dipl.-Ing. J. Kranz
4 23.04.2013
Todays challenges
1970 1985 2000 2015
1970 1985 2000 2015
1970 1985 2000 2015
diversity of
variants and
complexity
product
lifecycle
commodity
price
1970 1985 2000 2015
development
time
1970 1985 2000 2015
lot size
1970 1985 2000 2015
cost per
part
conventional
manufacturing
sources: EOS, communityspark.com, zetec.de, prairieecothrifter.com, productiveflourishing.com, wikimedia.com, european-americanblog.blogspot.com
EATC 2013
Dipl.-Ing. J. Kranz
5 23.04.2013
Basic principles of Laser Additive Manufacturing
source: Leistner
slicing 3D-CAD
powder layer
application
exposure
lowering
part
extraction
recoaterlifting table
scannerpart
support structures
thermal induced stresses
EATC 2013
Dipl.-Ing. J. Kranz
6 23.04.2013
Laser Additive Manufacturing (LAM) - Advantages
simple data preparation directly out of CAD-files
freedom of geometry
– lightweight – design
– structural optimization
– integration of functions
simultaneous manufacturing of various
individual parts
net-shape-manufacturing
high material recyclability
reduction of time-to-market
EATC 2013
Dipl.-Ing. J. Kranz
7 23.04.2013
manufacturing restrictions
often unknown
Barriers: Lack of design guidelines
development of DFM guidelines
necessary
EATC 2013
Dipl.-Ing. J. Kranz
8 23.04.2013
Barriers: current optimization tools do not
incorporate LAM specific restrictions
source: Altair
without
maximum
member size
with
maximum
member size
α
? distortion
cantilever beam
EATC 2013
Dipl.-Ing. J. Kranz
9 23.04.2013
Barriers: Conventional CAD – design process
unsuitable for LAM
conventional CAD-design primarily limited to simple boolean operations
conventional CAD-tools provide a parametrized approach ideal for product families
limited to simple basic elements for additive and subtractive geometry manipulation
complex freeform geometries hard to realize
EATC 2013
Dipl.-Ing. J. Kranz
10 23.04.2013
Barriers: Conventional wireframe based
CAD – modelling conditionally suitable for LAM
wireframe modelling facilitates freeform design but is complex
modelling based on curves and wireframe models
high geometrical modelling flexibility with a very time intensive modelling process
can be combined with conventional modelling
wireframe modelling
EATC 2013
Dipl.-Ing. J. Kranz
11 23.04.2013
Chances: new approaches for lightweight design
requirements
structural optimization
interpretation of results
remodelling in CAD
FE - analysis
final design
shift of manufacturing boundaries
geometrically complex framework design
manufacturing by conventional processes hardly possible
Implementation of complex biomimetic structures possible
EATC 2013
Dipl.-Ing. J. Kranz
12 23.04.2013
Chances: Application of biomimetics
source: sciencefoto.de, Nachtigall, Hill, Matheck, bambus.de
EATC 2013
Dipl.-Ing. J. Kranz
13 23.04.2013
Chances: Catalogue for structural biomimetics
systematical database optimizes the design process
Auswahl
nach
Belastung
2. loading
Auswahl
nach Form1. form
3. lightweight
design
principles
1. form
2. load
3. Leichtbau-
prinzipien bird‘s bone
optimization result
catalogue structure
technical
abstraction
EATC 2013
Dipl.-Ing. J. Kranz
14 23.04.2013
Chances: new approaches for lightweight design
weight saving
conventional design,
Al 7075
337.5 g
LAM, TiAl6V4 250 g
26 %
bamboo struture
requirements
structural optimization
interpretation of results
remodelling in CAD
FE - analysis
final design
EATC 2013
Dipl.-Ing. J. Kranz
15 23.04.2013
Successful testing of the LAM design conducted
F [kN]
16
22.4
requirement applied load
EATC 2013
Dipl.-Ing. J. Kranz
16 23.04.2013
Further lightweight studies
substitution by
optimization and bionic design
integrative design
Source: Airbus
Source: Airbus
F
F
EATC 2013
Dipl.-Ing. J. Kranz
17 23.04.2013
number of optimized brackets 120
accumulated weight saving 85 kg
average additional cost
[state-of-the-art machines] + EUR 312.-/kg
average additional cost
[next machine generation] + EUR 133.-/kg 0
10
20
30
2 3 4 5 6 7 8 9 10 11 12 13 14
Industrial building speed (cm³/h)
Production time/part (h)
1 part/job10
parts/job
results of A350 Business Case emphasize potential of laser additive
manufacturing in aviation industry
Airbus A350 Business Case – Economic feasibility of
laser additive manufacturing
1
1
2 4
2
2
1 1
1 1
2 2
7
2
1
3
6
2 2
1
2 2
1
1 1
1
EATC 2013
Dipl.-Ing. J. Kranz
18 23.04.2013
Chances: manufacture for design
manufacture for design approach requires new methods for product development
EATC 2013
Dipl.-Ing. J. Kranz
19 23.04.2013
Conclusion
available tools for product design not fully suitable for LAM
specific methods and tools need to be developed in order to further
exploit the processes advantages
the combination of LAM, structural optimization and biomimetics
enables high lightweight potential
LAM shows significant economical and ecological potential for
production
EATC 2013
Dipl.-Ing. J. Kranz
20 23.04.2013
Dipl.-Ing. Jannis Kranz
Technische Universität Hamburg Harburg
Denickestraße 17 (L)
21073 Hamburg
The research project “TiLight” on which the results are based is
funded by the “Bundesministerium für Bildung und Forschung"
under the support code 03CL20A
Thank you for your attention
source: ESA