Methodologies for Qualification of Additively Manufactured ...
LightHinge+: Additively manufactured lightweight hood...
Transcript of LightHinge+: Additively manufactured lightweight hood...
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LightHinge+:
Additively manufactured lightweight hood hinge
with integrated pedestrian protection
Sebastian Flügel | EDAG Engineering GmbH | HANNOVER MESSE | 26.04.2018
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EDAG Engineering GmbH: Portfolio
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 2 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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EDAG Engineering GmbH: AM projects
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 3 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Power electronic
housing [2013]
Hybrid Power Electronic
Housing [2015]
EDAG Genesis [2014]
EDAG Light Cocoon [2015]
Next-Gen Spaceframe [2015]
GenLight [2015]
Next-Gen Spaceframe 2.0 [2017]
Classic Cars [2016]
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 4
Introduction
active engine hood | project team
Engineering
conception | topology optimization | design | prototyping | testing
Process simulation
calibration | model setup | simulation | compensation | validation
Conclusion
outlook | award
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Agenda
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 5
Introduction
active engine hood | project team
Engineering
conception | topology optimization | design | prototyping | testing
Process simulation
calibration | model setup | simulation | compensation | validation
Conclusion
outlook | award
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Agenda
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Introduction: Active engine hood lifting system
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 6
■ Active engine hood lifting systems are
established as an important pedestrian
protection device in mass production
■ Reasons against use in small-series and
sports cars:
■ complex kinematics
■ many components
■ high weight
■ negative impact on design
■ high costs for small quantities
Active hood systems are rarely used in the small-series and
sports car segment
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
example:
https://www.youtube.com/watch?v=E4hIkEmtZ8U&index=
5&list=PLWRABoOo98KQiHsECrNzf4836P9eKYXmO
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Introduction: Project team
EDAG Engineering GmbH
■ Initiator and independent engineering company
■ Experts for lightweight construction and additive
manufacturing
■ Project lead, concept and component development
voestalpine Additive Manufacturing Center GmbH
■ Material supplier and AM contract manufacturer
■ Prototype production and AM know-how
simufact engineering GmbH
■ Simulation software provider for manufacturing processes
■ Distortion minimization through Simufact Additive
Software
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 7 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
With kind support from:
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 8
Introduction
active engine hood | project team
Engineering
conception | topology optimization | design | prototyping | testing
Process simulation
calibration | model setup | simulation | compensation | validation
Conclusion
outlook | award
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Agenda
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Engineering: Conception
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 9 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
DE: https://www.youtube.com/watch?v=2z-3vqAKkBU ENG: https://www.youtube.com/watch?v=n1tm-fwFmO4
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■ Topology optimization for weight reduction
■ Resulting in a support volume of over 50 %
■ Support reduction due to design adaptations
■ 1st step: 30 %
■ 2nd step: < 18 %
Engineering: Topology and support structure optimization
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 10
Support reduction for low post-processing and low costs
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
ca.
30 %
ca.
50 %
for
<18 %
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Engineering: Design
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 11 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
■ Maximum component and function integration in a design- and
weight-competitive package
■ Use of bionic principles
■ E.g. tension triangle method and tree branching according to C. Mattheck
■ Integrated pedestrian protection
■ Predetermined breaking elements for an additional degree of freedom
pedestrian protection function
50
hose guide
screw guide
connection point
gas pressure spring
opening fuction
breaking elements (detail A)
lightweight construction potential
function integration
cost impact
Sustainability & resource efficiency
detail A: breaking elements
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Engineering: First print job
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 12 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
DE: https://www.youtube.com/watch?v=2z-3vqAKkBU ENG: https://www.youtube.com/watch?v=n1tm-fwFmO4
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Engineering: Testing
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 13 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
DE: https://www.youtube.com/watch?v=2z-3vqAKkBU ENG: https://www.youtube.com/watch?v=n1tm-fwFmO4
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■ 720 g
■ 6
■ very low
■ low
■ weight: 1.490 g
■ number of components: 19
■ tied-up capital: high
■ needed package: high
Engineering: The result
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 14
Lightest construction for a hood hinge
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
- 51 %
- 68 %
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 15
Introduction
active engine hood | project team
Engineering
conception | topology optimization | design | prototyping | testing
Process simulation
calibration | model setup | simulation | compensation | validation
Conclusion
outlook | award
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Agenda
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Process simulation: Calibration of manufacturing process loads
■ Cantilever specimens with different scanning strategies were printed by voestalpine.
■ The cantilevers were cut and the deformation measured.
■ Deformations were translated into .
■ The inherent strains that reflect the manufacturing process loads were calibrated.
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 16 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Inherent strains are optimized
until they reproduce the test
results.
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Process simulation: Model setup for AM simulation
■ Import part geometry
■ Import support structure geometries
■ Select material from database – 316L steel
■ Define process chain to be simulated (build part, cut from plate, remove supports)
■ Mesh geometries with voxels
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
1200 k Elemente 600 k Elemente
Unterteil Oberteil
0.5 mm voxel mesh
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Process simulation: AM simulation of single parts
■ Simulation of
■ Building of the part
■ Cutting from plate
■ Removing support structures
■ Calculation times
■ Lower bracket
■ 13.6 hrs on 14 cores
■ Upper bracket
■ 8.6 hrs on 8 cores
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
https://www.youtube.com/watch?v=VJaFm7Fj8Dw
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Process simulation: AM simulation results
■ Model is stabilized as it loses its
reference after being cut from the
plate
■ Therefore displacement values
are not unique, but dependent on
relative position to original mesh
■ Nevertheless prediction of part
distortion is unaffected
Unterteil
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 19 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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Process simulation: AM simulation results
■ Effective stresses shown
■ Stresses are calculated based on
non-linear elastic-plastic material
model with realistic stress-strain
relationship (flow curve)
■ Yield stress at 585 MPa ■ Plastification leads to permanent
deformation = distortion
■ Ultimate strength is 685 MPa
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 20 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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Process simulation: Pre-deformed shape for distortion compensation
■ Simulated distortion is
inverted
■ Inverted distortion is mapped
on surface STL
■ Pre-distorted STL is exported
■ Exported STL was used for
optimized AM of distortion
compensated parts
NB: shown distortions are
overscaled by a factor of 10 for
better visualization
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 21 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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Process simulation: Distortion compensation
Original distortion of manufactured part vs. CAD Distortion compensated based on simulation results
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 22 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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Process simulation: Distortion compensation
Original distortion of manufactured part vs. CAD Distortion compensated based on simulation results
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 23 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 24
Introduction
active engine hood | project team
Engineering
conception | topology optimization | design | prototyping | testing
Process simulation
calibration | model setup | simulation | compensation | validation
Conclusion
outlook | award
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Agenda
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Conclusion: Process simulation
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 25
■ Significant reduction of the initial distortion up to 80% by AM simulation
■ Further improved results possible by additional simulation iterations
(Only one in project)
■ No necessity for building expensive and time consuming trial parts
■ No necessity for expensive compensation of distortion based on optical
measurements
■ AM part can already be within the given tolerances after the first build job
Manufacturing time and costs are reduced dramatically
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
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Conclusion: Engineering
© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 26
■ Safety and lightweight construction combined in a distortion- and
production-optimized design
■ Exploiting the full potential of additive manufacturing
■ Rethinking applications from scratch
■ Solving problems and generating added value
■ Apply to visible components in order to be recognizable to end customers
Preparing the way for automotive small series production
vertraulich Flügel Sebastian, CC Leichtbau, 02/2018
Topology
opimization
Design Distortion
minimization
Idea creation Active hood
function
Manufacturing Testing and
validation
Support
minimization
DE: https://www.youtube.com/watch?v=2z-3vqAKkBU ENG: https://www.youtube.com/watch?v=n1tm-fwFmO4
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© Copyright 2017 EDAG Engineering GmbH. All rights reserved. Folie 27 vertraulich Flügel Sebastian, CC Leichtbau, 02/2018