Embed Size (px)
DESCRIPTION
Additive manufacturing technologies allows to get rid of pre-existing manufacturing restrictions that previously have limited a designer’s ability to make the product they had in mind. With these processes, products can be highly customized to the user thus, potentially increasing their applications. As additive manufacturing technologies evolve, and more new materials become available the field of product design has the potential to greatly change. In order to fully exploit the capabilities of these technologies the application of the term “design freedom” for weight reduction as well as functional optimizations takes up a key role. FEM tools such as Altair Inspire provide the possibility to design parts, purely based on boundary conditions taking full advantage of the possibilities provided by additive manufacturing. The presentation will show the application of such a numerically supported part design covering the complete process chain from idea to a “ready to fly” product. The potential of weight savings and lead time reduction as well as future needs in order to close existing gaps in the design process are addressed.
Citation preview
Additive Manufacturing - Lessons Learned
European Altair Technology Conference 2014
Andreas Nick, APWorks GmbH
25.06.2014
Acknowledgements: Airbus Group Innovations TX2
Airbus Cabin Innovation & Design (ECIU1)
APWorks – feel the power of AIRBUS Group technologies
APWorks GmbH - Advanced Process Solutions
Page 2
02.07.2014
In light of the increasing amount of new, complex
technologies and manufacturing process solutions
available within AIRBUS Group, APWorks GmbH was
founded to leverage this knowledge, offering it to the
outside world.
As a 100% AIRBUS Group subsidiary, the company
maintains close working relationships with the AIRBUS
Group research and technology arm, AIRBUS Group
Innovation, as well as the corporation’s divisions Airbus,
Airbus Helicopters, and Airbus Defense & Space.
Located near Munich, Germany, at the Ludwig Bölkow
Campus, which pools high technology initiatives
together, APWorks is situated in close proximity to
AIRBUS Group divisions and other high tech companies
such as IABG and Siemens.
The Future by Airbus – The Airbus Concept Plane
APWorks GmbH - Advanced Process Solutions
Page 3
02.07.2014
5 Core Technology Themes
APWorks GmbH - Advanced Process Solutions
Page 4
02.07.2014
ATMOSPHERE
•Natural Lighting
•Bioluminescence/Surface Lighting
•Nano System Technology
•Aerosol Dispenser
ADVANCED MATERIALS
•Healthy Fabric & Interior Membranes
•Recyclability & Hygiene
•Morphing / Self-healing
• Transparent / Electro-chromatic /
Interactive Surfaces
INTELLIGENT DATA CONTROL
•Neuronal Network / Quantum Comp
• Sensors & Actuator (health monitoring)
• Energy Harvesting
•Holographics / NextGen HMI /
Augmented Reality
BIONIC PRINCIPLES
• Intelligent structures (“strength were
needed”)
• Structural Integrated Functions
• Living organism: adaptive
•Artificial Intelligence
SUSTAINABLE
ARCHITECTURE
Core Enabler for a Future Cabin Architecture
BIONICS Intelligent weight optimized bird bone structures providing strength
where needed
NEURAL NETWORK Neural networks sense & allow an optimum adaption of the cabin
along energy harvesting and regeneration
CABIN MEMBRANE Biopolymers harmonize external and internal environment for
optimized cabin atmosphere
APWorks GmbH - Advanced Process Solutions
Page 5
02.07.2014
Optimization of single parts
APWorks GmbH - Advanced Process Solutions
Page 6
02.07.2014
New design principles in combination with new manufacturing
technologies get mature today!
Enabling a Future Cabin Architecture
APWorks GmbH - Advanced Process Solutions
Page 7
02.07.2014
Build structures as nature would do it
DNA building blocks Human Skelton (rivitless)
CNT building blocks Large rivitless airframe
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 8
02.07.2014
COST
Titanium Price
Material Waste with traditional Manufacturing
90%
waste
90%
waste
90%
waste
Titanium Plate
TIME
QUALITY
BENEFITS & CAPABILITIES
Weight Savings Unique Geometric Capability New Materials
Material Price increasingly expensive
0.89kg 0.35kg
Material Waste with AM
Additive Manufacturing
guarantees high flexibility
in design as modifying a
part in retrospective only
requires changing the
virtual CAD data. PROGRAMME RISK MITIGATION
Data Release DFM Complete Dies / Patern
Complete First Production Article
Up to 95 weeks for large / complex parts
Opportunity for design changes or risk mitigation ~12 weeks
Forging / Investment Casting
AM
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 9
02.07.2014
APWorks controls each phase of the AM value chain with customized services generating superior results:
• Concept Development & Consulting
• Prototyping & Job Shopping
• Powder Sales
• Demonstration Center
APWORKS OFFER
high performance
Al- alloy
low performance
Al- alloy
End of
Part‘s Life
AM
Design
Quality
Assurance
Process & Post
processes
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 10
02.07.2014
APWORKS OFFER: AM VALUE CHAIN
During the design phase, a 3D part concept is developed.
Detailed design, engineering and simulation knowhow is needed to optimize
and fine-tune the part’s design for structure, flow, cooling and RF efficiency.
Depending on the material/part being considered, the most appropriate
additive process is selected.
Finally, different printing rules are applied in terms of orientation, support,
powder removal and nesting, when preparing the part for printing.
Stage 1
AM Design
Part Concept
Detailed Design,
Optimization
Process Selection
Build Design
& Preparation
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 11
02.07.2014
APWorks has invested in state-of-the-art systems to secure highest quality
powder production and supports the development of new materials / alloys.
With extensive in-house facilities and a developing supply chain, APWorks is
able to offer a wide range of AM processes.
With extensive experience and the facilities to perform surface treatment,
APWorks ensures long term performance of AM parts.
Heat treatment is an important factor in determining the performance of an
AM part, and APWorks has extensive facilities and experience to ensure that
the quality you require can be achieved.
The influence of finishing processes on the optimum part design is often
forgotten during the design phase. By managing design and post-processing
phases we can achieve the most efficient solution.
Most parts have some areas where machining processes are required in
order to achieve precise tolerances. By managing the design and
manufacturing steps, APWorks ensures that this is catered for.
APWORKS OFFER: AM VALUE CHAIN Stage 2
Process & Postprosses
Material Production
& Qualification
Heat & Preassure
Treatment
Machining of
Interfaces
Part Removal
from Plate
Surface Treatment
AM Process
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 12
02.07.2014
Stage 3
Quality assurance
Destructive testing
Non-destructive
testing
Finished part
Validation testing
Metrology
APWorks testing facility is also used for component validation testing, and
depending upon customer requirements a test rig can usually be developed to
support part qualification.
Dimensional validation is an important step in the manufacturing process, and is
possible even for complex parts using laser scanning and micro CT methods.
APWorks has an extensive testing facility, enabling AM specimens to be tested
in order to validate the material quality from the process, providing confidence to
the customer.
APWorks also has the latest micro-CT technology available to enable detailed
non-destructive examination of even the most complex parts.
By controlling the entire value chain, APWorks ensures the delivery of high
quality final parts. Even after delivery of the finished part, after-sales services
are available.
APWORKS OFFER: AM VALUE CHAIN
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 13
02.07.2014
Repair
Recycle
End of life
Repair processes are being developed to help extend product life in case of
damage, and minimize environmental impact.
Recycling is an important factor in today’s world, and we are developing the
means to recycle end-of-life products back into qualified powder for re-use.
APWORKS OFFER: AM VALUE CHAIN
Topology Optimization
APWorks GmbH - Advanced Process Solutions
Page 14
02.07.2014
Define Design Space and Boundary Conditions
Boundary Conditions
Loads Design Space Original Part
Topology Optimization
APWorks GmbH - Advanced Process Solutions
Page 15
02.07.2014
FEM Optimization Results
Safety Factor = 2 Safety Factor = 3
Topology Optimization
APWorks GmbH - Advanced Process Solutions
Page 16
02.07.2014
Design Interpretation
Key influences
• Design for additive manufacturing
Minimize support structures
Minimize residual stresses
Minimize machine time
• Minimize weight
• Minimize surface area
Topology Optimization
APWorks GmbH - Advanced Process Solutions
Page 17
02.07.2014
Result
Weight reduction > 45%
Material – Al7XX sheet –
Manufacturing Laser cutting
and bending
Weight – 81g
Material – AlSi10Mg
Manufacturing – ALM
Weight – 43g
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 18
02.07.2014
TOPOLOGY OPTIMIZATION PROCESS
Material – 15-5PH Steel
Manufacturing – Casting +
Welding
Weight – 1.57kg
Material – Titanium 6/4
Manufacturing – ALM
Design - Symmetric
Weight – 0.747kg
G250 Main Exit Door
Hinge
45% reduction in required
time through use of MMP
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 19
02.07.2014
TOPOLOGY OPTIMIZATION PROCESS
164 mm
65 mm
A350 FCRC Bracket
Connection
Material – TiAl6V4
Manufacturing – Machining
Weight – 0.37kg
Material – TiAl6V4
Manufacturing – ALM
Weight – 0.21kg
Additive Manufacturing
APWorks GmbH - Advanced Process Solutions
Page 20
02.07.2014
TOPOLOGY OPTIMIZATION PROCESS
Material – HC101 Steel
Manufacturing – Casting
Weight – 0.97kg
Material – Titanium 6/4
Manufacturing – ALM
Weight – 0.36kg
A320 Nacelle Hinge
APWorks GmbH - Advanced Process Solutions
Page 21
02.07.2014
Further Information
Andreas Nick
+49-89-60724502
www.apworks.de
