4 results
Filters
Settings
Now showing1 - 4 of 4
- Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Optimization of large-scale aeroengine parts produced by additive manufacturing(American Institute of Aeronautics and Astronautics (AIAA), 2024-01); ; ; ; Additive Manufacturing (AM) presents a ground-breaking opportunity to produce lightweight parts with enhanced functionality and design flexibility. It revolutionizes assembly by enabling integrated designs that significantly reduce component counts, minimizing assembly efforts and potential faults. Consequently, AM stands out as an appealing choice for manufacturing aerospace engine parts. Among AM techniques for metal parts, Laser Powder Bed Fusion (LPBF), also known as Direct Metal Laser Melting (DMLM), currently dominates the industry due to its capability to achieve high part quality and density using advanced machinery. However, limitations in part size stem from the build envelopes of these machines. Hence, this study explores the feasibility of printing large-scale engine parts, covering the design process, additive manufacturing, and aerothermal testing. A turbine center frame, nearly one meter in diameter, serves as a demonstrator case. Employing a multi-objective Design for Additive Manufacturing (DfAM) approach, the frame's structure underwent optimization through generative design, aiming to minimize mass, maximize stiffness, and meet strength requirements. Furthermore, the manifold section of the frame was optimized to reduce system pressure loss within the designated design space. Inconel 718 using LPBF was selected, with initial segments confirming manufacturability. The manufacturing process was fine-tuned for productivity and part properties, establishing design guidelines accordingly. Subsequently, the optimized manifold design underwent successful aerothermal testing on a specific test rig under various flow conditions. The redesigned frame showcased a 34% weight reduction and a 91% decrease in pressure loss while consolidating over 100 parts into one assembly. For the production, two alternatives are discussed. On the one hand, the final design was printed using the GE Additive ATLAS, the largest available LPBF system, validating the AM feasibility for large-scale parts under controlled laboratory conditions. On the other hand, a modified design is proposed that allows for the printing of segments on a regular-sized AM machine and a subsequent welding.Publicationtype: Conference Paper35 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Recycling of Ti-6Al-4V Powder in Metal Binder Jetting(Japan Society of Powder and Powder Metallurgy, 2024); ; ; Powder in sinter-based metal binder jetting is not fused but only bonded, which in principle ensures full reusability of the unbonded powder. This increases both resource and cost efficiency. In order to explore this potential, this study investigates the effect of powder recycling with regard to handling and thermal influences. For this purpose, a gas atomized Ti-6Al-4V powder is used as a reference powder. It is shown that recycling the Ti-6Al-4V powder four times leads to a minor change in the particle size distribution and an improvement in flow properties. No differences in the average green part densities could be determined, but an increase in their range (from 1 % to up to 7 %). Furthermore, it is demonstrated that the thermal influence due to curing and conditioning (temperatures ≤ 200°C) after printing does not lead to a significant increase in oxygen or nitrogen even after 15 repetitions.Publicationtype: Conference Paper66 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Automated design of 3D-printed silicone parts : a case study on hand rehabilitation gloves for stroke patientsThis paper presents an innovative way to customize silicone products by utilizing a design automation process and extrusion-based silicone 3D printing as a manufacturing technique. A customizable rehabilitation glove for stroke patients is used as an example to demonstrate the process chain. Soft robotics offers unique possibilities for the use of rehabilitation devices in a homecare setting and has the potential to support the healing process throughout the different steps of neurorehabilitation. Furthermore, customization of such devices can make physical therapy more comfortable and effective for the patient. The presented process chain combines pose detection with parametric design in order to adapt a glove consisting of soft bending actuators to the hand of a patient, which can be manufactured in a single day.Publicationtype: Book part19 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Methodology for integrating biomimetic beams in abstracted topology optimization results(American Society of Mechanical Engineers (ASME), 2022-10); ; ; ; This paper presents a five-step design methodology to generate designs of biomimetic structural components from topology optimization results. In step one, all material allocated by topology optimization is classified as either beam like structures or nodes to generate an auxiliary model consisting of preserved regions, cylindrical beams, and ball nodes, which is an abstraction of the original topology optimization result. In step two, the auxiliary model is exposed to the original boundary conditions in a finite element analysis. Then, internal forces, torsion, and bending moments in all beams of the auxiliary model are identified with respect to both of their ends. In step three, a database is used to find a suitable biomimetic beam for each previously analyzed beam in the auxiliary model. In step four, adapted nodes are designed to connect the biomimetic beams and preserved regions to generate an intermediate biomimetic component design. And in step five, a design iteration and a validation of the final design are performed. The design methodology allows for reproducible bio-mimetic component designs, a trackable and easily documentable component development process, and the possibility of automating the design process to ultimately save development costs when designing structural components.Publicationtype: Conference Paper55 178