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CaCS

Concept and Case Studies 2017/2018

Funding: Direct Manufacturing Research Center (DMRC)

Duration: 01/2017 - 12/2018

Description

Additive Manufacturing (AM) is a manufacturing process that is characterized in particular by the great creative freedom in product design. In order to make full use of all the possibilities that arise, both potentials and challenges must be known and taken into account in product design. The project "Concept and Case Studies" is concerned with the development of function-oriented principles of action especially for additive manufacturing, which support the design process of AM-compatible components. The developed active principles will be verified by means of demonstrators and the potential of function-oriented AM design in industrial applications will be investigated.

 

[Translate to English:] Abbildung 1: Konzept und Vorgehen

A three-step procedure is used to achieve the project objectives (Figure 1). First of all, the general consideration and research of the respective focused topic area is carried out. Based on this, the identification of suitable principles of action takes place. These operating principles, as well as practice-relevant descriptions and application examples, are summarized in a standardized catalogue. The most promising concepts are selected for further investigation on demonstrators. Figure 2 shows various demonstrators that were developed within the framework of CaCS 2017.

 

[Translate to English:] Abbildung 2: Demonstratoren für die Themenbereiche Wärmeübertragung und Strukturoptimierung

In 2017, the project focused on the topics "heat transfer" and "structural optimization", in 2018 the focus is on "influencing the magnetic flux" and "structural damping". In the long term, the project will look at other topics to support engineers in the design of new products and to make the advantages of AM tangible and applicable.

Objectives

  • Derivation of function-oriented principles of action for defined subject areas, by which the potentials of additive manufacturing can be better exploited in product design
  • Development of case studies relevant for industry to illustrate the practical application of the developed principles of action
  • Analysis of the design drafts with regard to a possible increase in performance and comparison of AM-compatible design with conventionally manufactured components

Research at C.I.K.

Research into structural optimization was primarily the responsibility of the C.I.K. Here, it was possible to fall back on many years of research in the field of topology optimization for additive manufacturing (cf. New Structure and OptiAMix). In this context, three of the five demonstrators were extensively redesigned and new solutions were developed based on the requirements. These range from a dedicated structural optimization (Figure 2, Part 5), a life cycle oriented optimization from automotive engineering (Figure 2, Part 1) to a combination of structural and thermal optimization (Figure 2, Part 3).

Especially in the area of coupled optimization of components for the integration of thermal management with structural elements, an important component for the application of additive manufacturing could be achieved within the scope of this project. The automated creation of optimal geometries for this purpose offers great potential for the material-saving optimization of heat- and structure-loaded components.

In 2018, research will focus on the field of structural damping of components. As a demonstrator, a mounting bracket for engine attachments will be machined here to increase the vibration-based fatigue strength.

Contact person

Manuel Ott, M.Sc.

Computeranwendung und Integration in Konstruktion und Planung

Manuel Ott
Phone:
+49 5251 60-3683
Fax:
+49 5251 60-3206
Office:
P1.3.27

Office hours:

Nach Absprache per E-Mail

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