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© Fraunhofer ILT DPP - Optimization potentials by Laser based manufacturing Simon Merkt Altair Conference 2013
| Date post: | 29-Nov-2014 |
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Technology |
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© Fraunhofer ILT
DPP - Optimization potentials by Laser based manufacturing
Simon Merkt Altair Conference 2013
© Fraunhofer ILT
Agenda
Introduction und Motivation
Topology Optimization and Selective Laser Melting (SLM)
New needs
Conclusion and Outlook
© Fraunhofer ILT
Digital Photonic Production – “From Bits to Photons to Atoms”
Unique properties of light …
highest energy density
highest speed
shortest interaction (precision)
mass-less, force-less
best controllability (CAD to product)
© Fraunhofer ILT
Digital Photonic Production – Basic Principles
Cutting
Ablation AM Polishing Analytics
Welding Drilling Glass drilling
Laser
© Fraunhofer ILT
Additive Manufacturing – Selective Laser Melting
metal powder lowering the platform
melting of the powder
application of powder layer
metal part made of serial material
3D-CAD model subdivided into layers
© Fraunhofer ILT
Selective Laser Melting – Examples
Blankholder side panel
Pulley
Chassis component
Kinematics component
Blankholder
Blankholder
Holder gas-filled absorber
Closure clamp
Chassis component Damper intake
Luggage rack holder
Kinematics component seat adjustment
HKL hinge
Brake line holder
Hose holder
Heat protection blank steering gear
Source: N. Skrynecki, Kundenorientierte Optimierung des generativen Strahlschmelzprozesses, 2010
© Fraunhofer ILT
Technology potential of SLM
Product complexity
Conventional manufacturing
Lot size
Digital Photonic Production
Conventional manufacturing
Innovative business models
Individualisation for free Individualisation for free Complexity for free
Innovative products
Piece Cost Piece cost
Digital Photonic Production
© Fraunhofer ILT
Agenda
Introduction und Motivation
Topology Optimization and Selective Laser Melting (SLM)
New needs
Conclusion and Outlook
© Fraunhofer ILT
Topology optimization of an upright (1)
Conventional design
Topology optimization
dummy FEM model
Topology optimization
result Final design
© Fraunhofer ILT
Stub axle for Formula Student Team Running Snails (220 x 160 mm)
Material: AlMgSc (Scalmalloy® EADS trademark)
Dimension: app. 220 mm x 160 mm Weight: app. 400g
2,5 cm
Laser power: PL = 200 W PL= 500 W
Focus diameter: ds = 200 µm ds= 200 µm
Scanning velocity: vscan = 500 mm/s vscan = 1250 mm/s
Theoretical build-up rate: V = 5 mm³/s V = 12,5 mm³/s
x 2,5
Topology optimization of an upright (2)
© Fraunhofer ILT
SLM-manufactured upright
First AlMgSc (Scalmalloy®) part manufactured by HP-SLM Weight saving: approx. 20 %
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Upright comparison
Evaluation criteria 2011 2012
Manufacturing process High Speed Cutting Selective Laser Melting
Optimization technique Iterative design with FEM-analysis
Topology optimization withSIMP
Material AlMgCuZn15/F52 AlMgScZr
Tensile strengh (Rm) ~520 MPa ~500 MPa
Final weight 0.502 kg (100%) 0.420 kg (83,7%)
Performance Max. displacement:0.19 mmMax. Stress:184 MPa
Max. displacement:0.14 mmMax. Stress:124 MPa
© Fraunhofer ILT
Bionic upright for RWTH Formula Student Team
Material: AlSi10Mg Weight saving: approx. 30 %
© Fraunhofer ILT
Agenda
Introduction und Motivation
Topology Optimization and Selective Laser Melting (SLM)
New needs
Conclusion and Outlook
© Fraunhofer ILT
Topology Optimization
0,37 kg
46% CO2
Lattice structures
0,31 kg
37% CO2
Classic Design
0,8 kg
100% CO2
Source: Loughborough University, Econolyst Ltd.
Topology Optimization vs. Lattice structures design
© Fraunhofer ILT
New needs for current optimization software
Mesh dependancy minimum feature sizes restricted
SLM process restrictions
SLM specific mechanical properties
Data and format handling
© Fraunhofer ILT
338 elements 13 min 13 s
Mesh dependency in topology optimization
21.000 elements 41 min 47 s
2.100.000 elements Ca. 48 h
© Fraunhofer ILT
Process restriction: Max. Overhang
Objective: Minimum build heigth
Material: AlSi10Mg
400 support structures
© Fraunhofer ILT
Video: Compression test of f2ccz-type structure
© Fraunhofer ILT
Agenda
Introduction und Motivation
Topology Optimization and Selective Laser Melting (SLM)
New needs
Conclusion and Outlook
© Fraunhofer ILT
Evaluation criteria AM Designguidelines
Lattice structuresdesign
Topologyoptimization
Functionaloptimization potential
Low Medium High
Resulting design Final design Final design Conceptual design
Simulation effort - Medium High
Automation Low Medium High
Traceability orintuitivity
High Low to Medium Low
Design verification Empirical formula Little empiricalformula available
FEM-based
Design approach comparison
Conclusion: Combination of all three approaches into one software tool
© Fraunhofer ILT
SLM-specific design tool
Force
Celluar design space
Thermically optimized intersection for force transmission
Solid shell
Powder outlet
y
x
© Fraunhofer ILT
New designs – Helicopter part
Material: 1.4404 (316L)
Fcc lattice structure
Weigth reduction: 50%
