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Cooperation Altair – EOS – EADS-IWTopology design of a metallic loadintroduction bracket manufactured by ALMWolfgang MACHU...
ABSTRACTINTRODUCTION• Bracket for High lift device• EOS: ALM ProcessSCALMALLOY®• Sc-modified & tailored AlMg-alloys• Stren...
INTRODUCTIONBracket for High lift deviceALM bracketPage 3 23/04/2013Topology design of metallic ALM bracketPage 3
INTRODUCTIONLoad introduction bracket• Release opening for drive strut bracket necessary in case of failure for laminar wi...
INTRODUCTIONProblem definition• Determine an ALM design for a metallic drive strut bracket considering all static andmanuf...
INTRODUCTIONEOS: ALM ProcessALM bracketPage 6 23/04/2013Topology design of metallic ALM bracketPage 6
INTRODUCTIONEOS: ALM ProcessSource: EOSAdditive Manufacturing – functional principleDirect – generative – resource efficie...
INTRODUCTIONEOS: ALM ProcessPage 8Topology design of metallic ALM bracket23/04/2013Source: EOS
INTRODUCTIONEOS: ALM ProcessKey differentiation criteria for laser sinteringFreedom of design Cost advantage Customization...
INTRODUCTIONEOS: ALM Process – Manufacturing constraintsDesign rules have to be considered to avoid supportstructures• Dep...
SCALMALLOY®ALM bracketPage 11 23/04/2013Topology design of metallic ALM bracketPage 11
Scalmalloy® ScalmalloyRP® Veryhigh strength Al-profiles High strength ALM AlMgSc alloysScalmalloySC®High performance sheet...
TOPOLOGY OPTIMIZATIONALM bracketPage 13 23/04/2013Topology design of metallic ALM bracketPage 13
TOPOLOGY OPTIMIZATIONDrive strut bracket – Load cases• 4 load cases considered for topology design in 90° (pressure – comp...
TOPOLOGY OPTIMIZATIONOptimization parameterObjective:• Min. weighted complianceConstraints:• VolFrac drive strut bracket: ...
TOPOLOGY OPTIMIZATIONProcess chainPage 16Topology design of metallic ALM bracket23/04/2013Non design room for bushingTopol...
TOPOLOGY OPTIMIZATIONFeasible Iso resultsPage 17Design and sizing of Krüger flap4/25/2013ISO 40 MPa ISO 30 MPaISO 10 MPaIS...
TOPOLOGY OPTIMIZATIONFeasible Iso resultsPage 18Design and sizing of Krüger flap4/25/2013Iso 0.85 Iso 0.65107 g 129 g+ low...
TOPOLOGY RESULT – POST-TREATMENTALM bracketPage 19 23/04/2013Topology design of metallic ALM bracketPage 19
TOPOLOGY RESULT – POST-TREATMENTSTL smoothing with HypermeshPage 20Topology design of metallic ALM bracket23/04/20131. OSS...
TOPOLOGY RESULT – POST-TREATMENTSTL smoothing with Hypermesh 12.0• The combination of a smoothing through OSSmooth and a r...
TOPOLOGY RESULT – POST-TREATMENTInterpretation of ALM support structure• According to slide 10 a support structure is need...
TOPOLOGY RESULT – POST-TREATMENTInterpretation of ALM support structure• Target should be to minimize the post treatment o...
TOPOLOGY RESULTManufactured ALM load introduction bracketPage 24Topology design of metallic ALM bracket23/04/2013
Thank you for you attention!Wolfgang MachunzeWolfgang.Machunze@eads.net+49 (0) 89-607 29580Page 25Thomas Lehmannlehmann@al...
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Topology design of a metallic load introduction bracket manufactured by ALM

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Transcript of "Topology design of a metallic load introduction bracket manufactured by ALM"

  1. 1. Cooperation Altair – EOS – EADS-IWTopology design of a metallic loadintroduction bracket manufactured by ALMWolfgang MACHUNZE – EADS Innovation WorksThomas LEHMANN – AltairPeter HEIN– EOS23. April 2013
  2. 2. ABSTRACTINTRODUCTION• Bracket for High lift device• EOS: ALM ProcessSCALMALLOY®• Sc-modified & tailored AlMg-alloys• Strength investigationsTOPOLOGY OPTIMIZATION• Model• Process chainTOPOLOGY RESULT – POST-TREATMENT• STL format• Support structurePage 2Topology design of metallic ALM bracket23/04/2013
  3. 3. INTRODUCTIONBracket for High lift deviceALM bracketPage 3 23/04/2013Topology design of metallic ALM bracketPage 3
  4. 4. INTRODUCTIONLoad introduction bracket• Release opening for drive strut bracket necessary in case of failure for laminar wing– Possibility to release screws in retracted position (a)– Hinge down of Krüger flap (b)– Demounting of Krüger flap (c)• Conventional milling design of load introduction bracket:Page 4Topology design of metallic ALM bracket23/04/2013
  5. 5. INTRODUCTIONProblem definition• Determine an ALM design for a metallic drive strut bracket considering all static andmanufacturing constraintsPage 5Topology design of metallic ALM bracket23/04/2013
  6. 6. INTRODUCTIONEOS: ALM ProcessALM bracketPage 6 23/04/2013Topology design of metallic ALM bracketPage 6
  7. 7. INTRODUCTIONEOS: ALM ProcessSource: EOSAdditive Manufacturing – functional principleDirect – generative – resource efficientFrom a 3D CADmodel…… to completeparts Application ofpowder Exposure byLaser Lowering ofplatform Re-application ofpowder Exposure byLaserWorks for plastics and metalsPage 7Topology design of metallic ALM bracket23/04/2013Source: EOS
  8. 8. INTRODUCTIONEOS: ALM ProcessPage 8Topology design of metallic ALM bracket23/04/2013Source: EOS
  9. 9. INTRODUCTIONEOS: ALM ProcessKey differentiation criteria for laser sinteringFreedom of design Cost advantage CustomizationOrganizationTime to marketLightweight Static: weight of parts Dynamic: moving,accelerated partsComplex components E.g. alternativestructures of heatexchangersIntegratedfunctionality Embeddedfunctionality withoutassemblyIndividualized parts Customer specificadaptations Cost efficient smallseries up tolot size oneRapid prototyping Fast feasibilityfeedback of virtualmodels Haptic feedbackPage 9Topology design of metallic ALM bracket23/04/2013Source: EOS
  10. 10. INTRODUCTIONEOS: ALM Process – Manufacturing constraintsDesign rules have to be considered to avoid supportstructures• Depending on the building direction supportstructures are required if the angle of buildingdirection falls below 45°• If angle below 45° a support structure will be builtbelow the real structure which need to be removedwithin a post treatmentPage 10Topology design of metallic ALM bracket23/04/2013
  11. 11. SCALMALLOY®ALM bracketPage 11 23/04/2013Topology design of metallic ALM bracketPage 11
  12. 12. Scalmalloy® ScalmalloyRP® Veryhigh strength Al-profiles High strength ALM AlMgSc alloysScalmalloySC®High performance sheet materialfor Airbus A3OX®Scalmalloy, ScalmallyRP & ScalmalloySC are registered trade marks (brands) of EADS, ScalmallySC &ScalmalloyRP are protected manufacturing schemes (EADS patents)SCALMALLOY®Sc-modified & tailored AlMg-alloys (by rapid solidification)• Scandium is the most potent reinforcing element for Al-alloys• Addition of 0,1wt% Sc enables a strength increase of ~ 50 MPa and a linear strengthincrement is reported for higher Sc contentsPage 12Topology design of metallic ALM bracket23/04/2013
  13. 13. TOPOLOGY OPTIMIZATIONALM bracketPage 13 23/04/2013Topology design of metallic ALM bracketPage 13
  14. 14. TOPOLOGY OPTIMIZATIONDrive strut bracket – Load cases• 4 load cases considered for topology design in 90° (pressure – compression on drive strut)and 122° (lift – tension on drive strut) setting• Interface loads drive strut bracket:23/04/2013Topology design of metallic ALM bracketPage 14
  15. 15. TOPOLOGY OPTIMIZATIONOptimization parameterObjective:• Min. weighted complianceConstraints:• VolFrac drive strut bracket: 0.4 (variable)• Element force tension screw > 0• Element force compression screw < 0Topology optimization:• MinDim: 8 mm (variable)• Stress constraint: 500 MPa (AlMgSc)• 1-plane symmetry• Extrusion direction  derived from first initial optimization stepPage 15Topology design of metallic ALM bracket23/04/2013
  16. 16. TOPOLOGY OPTIMIZATIONProcess chainPage 16Topology design of metallic ALM bracket23/04/2013Non design room for bushingTopology result Iso 0.85Which is the lightest ISO design?Automated routine to derivelightest ISO design which fits thedefined stress / strain / …constraintsReanalysis of topologyresult Iso 0.85  feasibledesign
  17. 17. TOPOLOGY OPTIMIZATIONFeasible Iso resultsPage 17Design and sizing of Krüger flap4/25/2013ISO 40 MPa ISO 30 MPaISO 10 MPaISO 20 MPa
  18. 18. TOPOLOGY OPTIMIZATIONFeasible Iso resultsPage 18Design and sizing of Krüger flap4/25/2013Iso 0.85 Iso 0.65107 g 129 g+ lower weight + minor support structure
  19. 19. TOPOLOGY RESULT – POST-TREATMENTALM bracketPage 19 23/04/2013Topology design of metallic ALM bracketPage 19
  20. 20. TOPOLOGY RESULT – POST-TREATMENTSTL smoothing with HypermeshPage 20Topology design of metallic ALM bracket23/04/20131. OSSmooth:Following settings:2. AutoMeshFollowing settings:3. Export STL file
  21. 21. TOPOLOGY RESULT – POST-TREATMENTSTL smoothing with Hypermesh 12.0• The combination of a smoothing through OSSmooth and a remeshing process inHypermesh 12.0 provides sufficient surface quality• To represent the geometry of freeform surfaces triangles with an edge length of up to0,001mm can be beneficial for the surface quality• Example with average edge length of 0.3 mm that was sufficientPage 21Topology design of metallic ALM bracket23/04/2013
  22. 22. TOPOLOGY RESULT – POST-TREATMENTInterpretation of ALM support structure• According to slide 10 a support structure is needed for the current design• Support structure generated by EOS software and experiencePage 22Topology design of metallic ALM bracket23/04/2013
  23. 23. TOPOLOGY RESULT – POST-TREATMENTInterpretation of ALM support structure• Target should be to minimize the post treatment of the ALM part• Support structure can be avoided if angle of material build up direction is above 45° usage of gothic structures• Can be achieved by morphing or direct integration within topology optimization processPage 23Topology design of metallic ALM bracket23/04/2013Support necessary No support necessaryGothic structures
  24. 24. TOPOLOGY RESULTManufactured ALM load introduction bracketPage 24Topology design of metallic ALM bracket23/04/2013
  25. 25. Thank you for you attention!Wolfgang MachunzeWolfgang.Machunze@eads.net+49 (0) 89-607 29580Page 25Thomas Lehmannlehmann@altair.de+49 (0) 7031-6208141Peter HeinPeter.Hein@eos.info+49 (0) 89-893 362230
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