Laser additive manufacturing of lightweight structures in TiAl6V4 – a design for manufacturing...
20
Development Consulting Education Research Laser additive manufacturing of lightweight structures in TiAl6V4: a design for manufacturing approach Dipl.-Ing. Jannis Kranz Dr.-Ing. D. Herzog Prof. Dr.-Ing. C. Emmelmann Munich June 25, 2014
-
Upload
altair-engineering -
Category
Engineering
-
view
1.000 -
download
8
description
Due to its high geometrical freedom additive manufacturing technologies offer a significant potential for lightweight applications, especially in the field of aviation. Yet, process specific restrictions and guidelines for the design, especially for metallic lightweight structures, are only marginally spread. Time and cost intensive iteration cycles until a process stable part manufacturing and an only insufficient use of the freedom in design can be the result. Addressing these shortcomings the presentation will show a DFM approach for LAM based on the VDI 2221. Supporting the designer in load and manufacturing suitable solutions by the implementation of DFM guidelines, structural biomimetic and topology optimization is the focus of this approach. The whole design process is covered and specifically supported by the implementation of LAM design guidelines. The presented approach will be shown by a demonstrator part.
Transcript of Laser additive manufacturing of lightweight structures in TiAl6V4 – a design for manufacturing...
Development
Consulting
Education
Research Laser additive manufacturing of
lightweight structures in TiAl6V4:
a design for manufacturing approach
Dipl.-Ing. Jannis Kranz
Dr.-Ing. D. Herzog
Prof. Dr.-Ing. C. Emmelmann
Munich
June 25, 2014
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
2
LZN Laser Zentrum Nord GmbH and
Institute of Laser and System Technologies (iLAS)
City of Hamburg,
Germany
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
3
agenda
1. Laser Additive Manufacturing
2. Design guidelines for LAM
3. Design process for LAM
4. Summary
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
4
Laser Additive Manufacturing (LAM):
basic principles
source: Leistner
one component materials
stainless steel, tool steel
aluminum
titanium and titanium alloys
(TiAl6Nb7,TiAl6V4)
slicing 3D-CAD
powder layer
application
exposure
lowering
part
extraction
recoaterlifting table
scannerpart
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
5
Laser Additive Manufacturing (LAM) - Advantages
simple data preparation directly out of CAD-files
simultaneous manufacturing of various
individual parts
net-shape-manufacturing
high material recyclability
reduction of time-to-market
freedom of geometry
– lightweight – design
– integration of functions
sae.org
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
6
Laser Additive Manufacturing (LAM):
new design freedom and challenges
conventional design freeform surfaces lattice structures
rise in design complexity
design know-how limitied to experts; lack of guidelines
part designs often influenced by conventional manufacturing restrictions
LAM requires process specific development method
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
7
agenda
1. Laser Additive Manufacturing
2. Design guidelines for LAM
3. Design process for LAM
4. Summary
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
8
Guideline catalogue for LAM:
identified challenges (excerpt)
Guideline focus: lightweight structures in TiAl6V4
bores
beam elements
roughness
post processing
hollow structures
walls
ribs
curvatures
beads
supports
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
9
LAM guideline catalogue:
experimental investigation – thin walls
exploitation of manufacturing constraints
evaluation of various specimen orientations
specimen: straight square walls
– thickness variation; homogenious heigth and width of 10 mm
– 90° β 30° → 0.4 mm producible
– at β = 30° → 0.3 mm producible
α β
d=0,2 mm
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
10
Guideline catalogue for LAM:
structure (excerpt)
Current catalogue includes more than 60 guidelines
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
11
agenda
source: isgatec.de
1. Laser Additive Manufacturing
2. Design guidelines for LAM
3. Design process for LAM
4. Summary
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
12
Design method for LAM:
General approach
structural
optimization
bionics
design
guidelines
LAM – specific
design method
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
13
Design method for LAM:
basic structure
List of requirements 1
Determination of constraints 2
Topology optimization 3
Inspection of optimization result 4
Interpretation of optimization result 5
Selection of structural principles 6
Concept modelling 7
Design verification 8
Result documentation 9
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
14
List of requirements 1
Determination of constraints 2
Topology optimization 3
Inspection of optimization result 4
Interpretation of optimization result 5
Selection of structural principles 6
CAD modelling 7
Design verification 8
Result documentation 9
Design method for LAM:
Demonstrator
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
15
Design method for LAM:
Interpretation of optimization results
identification of sub-structures
interpretation of optimization results
priorization of sub-structures
determination of orientation
5
interfaces, structural
volume and functionalities
analyzation of sub-structures
2. loading
interface 2
interface 1strut 1
strut 2
strut 3
shear field 1
shear field 2
shear field 3
strut 4
1. form
Structured optimization
result
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
16
Design method for LAM:
structural definition
bionic catalogue, common
design principles collect structural principles
structural principles: search,
evaluation and selection
structural solutions
select solution principles
evaluate structural principles
define substructure
6
DFM checklist
divide substructures manufacturing conflict
interface 2
interface 1strut 1
strut 2
strut 3
shear field 1
shear field 2
shear field 3
strut 4
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
17
Design method for LAM:
design demonstrator
Weight saving approx. 20 %
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
18
agenda
1. Laser Additive Manufacturing
2. Design guidelines for LAM
3. Design process for LAM
4. Summary
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
19
summary
LAM facilitates new approaches for lightweight design
user guidance due to complex process restriction in design process needed
basic design restrictions for LAM in TiAl6V4 were explored
integration of bionics, structural optimization and manufacturing restrictions in
a LAM specific design method
further exploitation of process limitations in following projects
The research project “TiLight” on which the results are based is funded by the “Bundesministerium für
Bildung und Forschung" under the support code 03CL20A
Laser additive manufacturing of lightweight structures in TiAl6V4:
a design for manufacturing approach; Dipl.-Ing. Jannis Kranz
20
Thank you very much for your attention!
Dipl.-Ing. Jannis Kranz
Technische Universität Hamburg-Harburg /iLAS
Am Schleusengraben 14
21029 Hamburg-Bergedorf
