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Mariia Grol, LLC LMTI UC RUSAL 3DEXPERIENCE IN RUSAL ADDITIVE CENTER: RESULTS AND IMPACT
Mariia Grol, LLC LMTI UC RUSAL
3DEXPERIENCE IN RUSAL ADDITIVE CENTER: RESULTS
AND IMPACT
COMPANY PRESENTATION March, 2018
United Company RUSAL is a low cost, vertically integrated, low CO2 aluminium producer with core smelting operations located in Siberia, Russia. In 2017, RUSAL was the world’s second largest producer of primary aluminium and alloys.
#1 ALUMINIUM PRODUCER OUTSIDE OF CHINA
RUSAL’s production chain includes bauxite and nepheline ore mines, alumina refineries, aluminium smelters and casting houses, wheels manufacturing, foil mills and packaging production centres as well as power-generating facilities.
WHO WE ARE
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Source: Based on RUSAL’sinternal Company report, andpeer companies’ publiclyavailable results,announcements, reports andother information.
5,9
3,7
33,2
3,6
2,42,3
2,4
2,1 2,1
7,5
3,73,7 3,7 3,6
2,5 2,42,3
2,1 2,1
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
Hongqiao RUSAL Chalco Xinfa Rio Tinto EGA SPIC Alcoa East Hope NorskHydro
2016
2017
TOP ALUMINIUM PRODUCERSmillion tonnes
COMPANY PRESENTATION March, 2018
NEW ALUMINIUM ALLOYS FOR ADDITIVE TECHNOLOGIES
Key p
art
ners
Medium Strength Alloys
High Strength Alloys
Heat Resistant Alloys
Alloy AlSi10MgRUSALRS-320
RUSALRS-356
σВ, MPa 320 405 300
σ0,2, MPa 215 260 195
δ, % 7,0 6,0 12
AlloyAirbus
ScalmalloyRUSALRS-553
RUSALRS-507
σB, MPa 490 475 430
σ0,2, MPa 450 435 340
δ, % 8 10 15
% Sc 0,7 0,3 -
Alloy AlSi10MgRUSALRS-390
RUSALRS-230
RUSALRS-970
σB20, MPa 350 360 490 260
σ0,220, MPa 215 265 430 270
T work °С 175 250 250 350
σBwork, MPa 140 170 170 200
Volgograd Shelekhov
RUSAL’s production facilities allow to produce up to 40,000 tonnes ofspherical powders per year. In particular, products in the d50 rangefrom1 to 100 microns.
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COMPANY PRESENTATION March, 2018
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ADDITIVE CENTER OF LMTIMain Equipment of the Additive Center
3D printer EOS M290Atomizer BluePowerAU12000
30 kg for aluminum
3D scanner KreonAce Skyline
Accuracy 15 μm
3DExperience Software
LMTI Test Center
Casting and heat treatment sector
Machining sector
Physical Properties Research LabHeat capacity, thermal, conductivity, thermal expansion coefficient
Mechanical Properties LabStatic strength for room temperature, with heating, HCF, LCF
Corrosion LabGeneral corrosion, climatic corrosion, fretting-corrosion
Metallography and Chemistry Lab
COMPANY PRESENTATION March, 2018
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OPTIMIZATION APPROACHES
Optimization
Parametric Structural
Topology optimization
Discretization of the model
Iterative solving of the simulation
Design concept
Verification analysis
Searching for parameter values to meet optimization criteria
Finding the best material distribution in the project area
COMPANY PRESENTATION March, 2018
Initial designMass: 0.641 kg
TOPOLOGY OPTIMIZATION OF THE ROCKER
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Part to optimize: the rocker for mechanization ofaircraft flap systems
Optimization goal: weight reduction to 0.45 kg withminimization of compliance for 4 load cases
Stress-strain state for the worst load case
BC 1Load 1
Load 2
BC 2
Loads and boundary conditions
COMPANY PRESENTATION March, 2018
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Model for optimization
Distribution of relative densities in the project
area for the last iteration
Automatically generated model
TOPOLOGY OPTIMIZATION OF THE ROCKER
COMPANY PRESENTATION March, 2018
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Comparison of initial and optimized design
Stress-strain state of optimized model for the worst case
A number of part concepts have been
generated and compared, the best one is chosen
Min safety factor for this part is 1.37(required minimum 1.3) Weight of initial part: 0.641 kg
Weight of optimized model: 0.427 кгWeight gain: 33%
TOPOLOGY OPTIMIZATION OF THE ROCKER
COMPANY PRESENTATION March, 2018
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PRINT PREPARATION
Performing the part layout and supports
Analysis of shape deviations during the printing process
COMPANY PRESENTATION March, 2018
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PARTS PRINTING
Printing of the rocker and other parts on the platform takes 42 hours
COMPANY PRESENTATION March, 2018
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Bench test of optimized part (8% of lifecycle time)
The boundary conditions were clarified(RBE3 was used instead of fixing degrees of freedom directly on mesh)
One more optimization is performed
The new design was obtained, verification simulation was carried out.
Inconsistency of the initial data resulted in wrong task definition an, as a result, wrong simulation
Optimization characteristics
Before After
Weight, kg 0,641 0,544*
Alloy AlSi7Mg RS-320
Density, g/cm3 2,7 2,7
Manufacturing method Casting 3D-printing
*minimum safety factor in the worst load case is 1,68. Weight gain 15%
TOPOLOGY OPTIMIZATION OF THE ROCKER
The part is printed and mounted on test bench
COMPANY PRESENTATION March, 2018
Questions?
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Maria [email protected]
Project managerDepartment of Additive Technologies
LMTI UC RUSAL +7(965)242-41-17
+7(495)720 5170 add. 1242
