structural optimization and laser additive manufacturing (lam) in lightweight design: barriers and...

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Engineering the Future… with Photons Development Consulting Education Research Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances Dipl.-Ing. J. Kranz Prof. Dr.-Ing. C. Emmelmann Turin, 23. April 2013

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Page 1: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

Engineering the Future…

…with Photons

Development

Consulting

Education

Research

Structural Optimization and

Laser Additive Manufacturing

(LAM) in lightweight design:

barriers and chances

Dipl.-Ing. J. Kranz

Prof. Dr.-Ing. C. Emmelmann

Turin, 23. April 2013

Page 2: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

2 23.04.2013

LZN Laser Zentrum Nord GmbH and

Institut of Laser and System Technologies (iLAS)

City of Hamburg, Germany

Page 3: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

3 23.04.2013

Agenda

1. Laser Additive Manufacturing

2. Current Barriers in Application

3. Chances for Lightweight Design

4. Conclusion

Page 4: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

4 23.04.2013

Todays challenges

1970 1985 2000 2015

1970 1985 2000 2015

1970 1985 2000 2015

diversity of

variants and

complexity

product

lifecycle

commodity

price

1970 1985 2000 2015

development

time

1970 1985 2000 2015

lot size

1970 1985 2000 2015

cost per

part

conventional

manufacturing

sources: EOS, communityspark.com, zetec.de, prairieecothrifter.com, productiveflourishing.com, wikimedia.com, european-americanblog.blogspot.com

Page 5: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

5 23.04.2013

Basic principles of Laser Additive Manufacturing

source: Leistner

slicing 3D-CAD

powder layer

application

exposure

lowering

part

extraction

recoaterlifting table

scannerpart

support structures

thermal induced stresses

Page 6: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

6 23.04.2013

Laser Additive Manufacturing (LAM) - Advantages

simple data preparation directly out of CAD-files

freedom of geometry

– lightweight – design

– structural optimization

– integration of functions

simultaneous manufacturing of various

individual parts

net-shape-manufacturing

high material recyclability

reduction of time-to-market

Page 7: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

7 23.04.2013

manufacturing restrictions

often unknown

Barriers: Lack of design guidelines

development of DFM guidelines

necessary

Page 8: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

8 23.04.2013

Barriers: current optimization tools do not

incorporate LAM specific restrictions

source: Altair

without

maximum

member size

with

maximum

member size

α

? distortion

cantilever beam

Page 9: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

9 23.04.2013

Barriers: Conventional CAD – design process

unsuitable for LAM

conventional CAD-design primarily limited to simple boolean operations

conventional CAD-tools provide a parametrized approach ideal for product families

limited to simple basic elements for additive and subtractive geometry manipulation

complex freeform geometries hard to realize

Page 10: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

10 23.04.2013

Barriers: Conventional wireframe based

CAD – modelling conditionally suitable for LAM

wireframe modelling facilitates freeform design but is complex

modelling based on curves and wireframe models

high geometrical modelling flexibility with a very time intensive modelling process

can be combined with conventional modelling

wireframe modelling

Page 11: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

11 23.04.2013

Chances: new approaches for lightweight design

requirements

structural optimization

interpretation of results

remodelling in CAD

FE - analysis

final design

shift of manufacturing boundaries

geometrically complex framework design

manufacturing by conventional processes hardly possible

Implementation of complex biomimetic structures possible

Page 12: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

12 23.04.2013

Chances: Application of biomimetics

source: sciencefoto.de, Nachtigall, Hill, Matheck, bambus.de

Page 13: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

13 23.04.2013

Chances: Catalogue for structural biomimetics

systematical database optimizes the design process

Auswahl

nach

Belastung

2. loading

Auswahl

nach Form1. form

3. lightweight

design

principles

1. form

2. load

3. Leichtbau-

prinzipien bird‘s bone

optimization result

catalogue structure

technical

abstraction

Page 14: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

14 23.04.2013

Chances: new approaches for lightweight design

weight saving

conventional design,

Al 7075

337.5 g

LAM, TiAl6V4 250 g

26 %

bamboo struture

requirements

structural optimization

interpretation of results

remodelling in CAD

FE - analysis

final design

Page 15: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

15 23.04.2013

Successful testing of the LAM design conducted

F [kN]

16

22.4

requirement applied load

Page 16: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

16 23.04.2013

Further lightweight studies

substitution by

optimization and bionic design

integrative design

Source: Airbus

Source: Airbus

F

F

Page 17: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

17 23.04.2013

number of optimized brackets 120

accumulated weight saving 85 kg

average additional cost

[state-of-the-art machines] + EUR 312.-/kg

average additional cost

[next machine generation] + EUR 133.-/kg 0

10

20

30

2 3 4 5 6 7 8 9 10 11 12 13 14

Industrial building speed (cm³/h)

Production time/part (h)

1 part/job10

parts/job

results of A350 Business Case emphasize potential of laser additive

manufacturing in aviation industry

Airbus A350 Business Case – Economic feasibility of

laser additive manufacturing

1

1

2 4

2

2

1 1

1 1

2 2

7

2

1

3

6

2 2

1

2 2

1

1 1

1

Page 18: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

18 23.04.2013

Chances: manufacture for design

manufacture for design approach requires new methods for product development

Page 19: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

19 23.04.2013

Conclusion

available tools for product design not fully suitable for LAM

specific methods and tools need to be developed in order to further

exploit the processes advantages

the combination of LAM, structural optimization and biomimetics

enables high lightweight potential

LAM shows significant economical and ecological potential for

production

Page 20: Structural Optimization and Laser Additive Manufacturing (LAM) in lightweight design: barriers and chances

EATC 2013

Dipl.-Ing. J. Kranz

20 23.04.2013

Dipl.-Ing. Jannis Kranz

[email protected]

Technische Universität Hamburg Harburg

Denickestraße 17 (L)

21073 Hamburg

The research project “TiLight” on which the results are based is

funded by the “Bundesministerium für Bildung und Forschung"

under the support code 03CL20A

Thank you for your attention

source: ESA