Details
| Original language | English |
|---|---|
| Title of host publication | Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology |
| Subtitle of host publication | EUSPEN 2021 |
| Editors | R. K. Leach, C. Nisbet, D. Phillips |
| Pages | 499-502 |
| Number of pages | 4 |
| ISBN (electronic) | 9780995775190 |
| Publication status | Published - 2021 |
| Event | 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021 - Virtual Conference, Copenhagen, Denmark Duration: 7 Jun 2021 → 10 Jun 2021 Conference number: 21 |
Abstract
Additive manufacturing (AM) processes have become increasingly important in recent years. Their application enables the manufacturing of individual, functional components using minimal material. In particular, AM processes are used for the manufacturing of lightweight structures in the aerospace industry. Apart from rare exceptions, the use of additively manufactured components in machine tools is not widespread. However, their functional lightweight design offers high potential for increasing productivity of machine tools. This potential is particularly high when components are frequently accelerated due to the possibility of reducing moments of inertia. This paper presents a concept of a topologically optimized, rotating, and mechanically high stressed lathe clamping system using the SLM (Selective Laser Melting) method. The topology optimization is performed numerically with the simulation software ANSYS. The additive materials applied are a stainless martensitic chrome-nickel steel (AISI 630) and an aluminum-silicon alloy (EN AC-43000). First, strength-relevant material characteristics are determined experimentally. The effects of different hardening processes on the material characteristics are predicted. These material properties are required for the parameterization of the clamping system simulation model. The modelling approach is described in the following. The simulation results of the non-optimized clamping system serve as a reference for evaluating the properties of the optimized system. The simulation model is then used to perform a mass-based topology optimization of four components of the clamping system with high moments of inertia. The components are evaluated simulatively with regard to their yield strength. As a result of the topology optimization, it is found that the moments of inertia of the components are reduced by up to 72%. Due to the functional, lightweight design of the clamping system, significant reductions in machining and non-productive time of up to 19% are possible.
Keywords
- Additive manufacturing, Lathe clamping system, Material testing, Topology optimization
ASJC Scopus subject areas
- Engineering(all)
- Industrial and Manufacturing Engineering
- Engineering(all)
- Mechanical Engineering
- Environmental Science(all)
- Environmental Engineering
- Materials Science(all)
- General Materials Science
- Physics and Astronomy(all)
- Instrumentation
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Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology: EUSPEN 2021. ed. / R. K. Leach; C. Nisbet; D. Phillips. 2021. p. 499-502.
Research output: Chapter in book/report/conference proceeding › Conference contribution › Research › peer review
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TY - GEN
T1 - Topology optimization of highly stressed machine tool components using the SLM process
AU - Denkena, Berend
AU - Bergmann, Benjamin
AU - Klemme, Heinrich
AU - Beyer, Ralf Eckhard
AU - Blunk, Heiko
N1 - Conference code: 21
PY - 2021
Y1 - 2021
N2 - Additive manufacturing (AM) processes have become increasingly important in recent years. Their application enables the manufacturing of individual, functional components using minimal material. In particular, AM processes are used for the manufacturing of lightweight structures in the aerospace industry. Apart from rare exceptions, the use of additively manufactured components in machine tools is not widespread. However, their functional lightweight design offers high potential for increasing productivity of machine tools. This potential is particularly high when components are frequently accelerated due to the possibility of reducing moments of inertia. This paper presents a concept of a topologically optimized, rotating, and mechanically high stressed lathe clamping system using the SLM (Selective Laser Melting) method. The topology optimization is performed numerically with the simulation software ANSYS. The additive materials applied are a stainless martensitic chrome-nickel steel (AISI 630) and an aluminum-silicon alloy (EN AC-43000). First, strength-relevant material characteristics are determined experimentally. The effects of different hardening processes on the material characteristics are predicted. These material properties are required for the parameterization of the clamping system simulation model. The modelling approach is described in the following. The simulation results of the non-optimized clamping system serve as a reference for evaluating the properties of the optimized system. The simulation model is then used to perform a mass-based topology optimization of four components of the clamping system with high moments of inertia. The components are evaluated simulatively with regard to their yield strength. As a result of the topology optimization, it is found that the moments of inertia of the components are reduced by up to 72%. Due to the functional, lightweight design of the clamping system, significant reductions in machining and non-productive time of up to 19% are possible.
AB - Additive manufacturing (AM) processes have become increasingly important in recent years. Their application enables the manufacturing of individual, functional components using minimal material. In particular, AM processes are used for the manufacturing of lightweight structures in the aerospace industry. Apart from rare exceptions, the use of additively manufactured components in machine tools is not widespread. However, their functional lightweight design offers high potential for increasing productivity of machine tools. This potential is particularly high when components are frequently accelerated due to the possibility of reducing moments of inertia. This paper presents a concept of a topologically optimized, rotating, and mechanically high stressed lathe clamping system using the SLM (Selective Laser Melting) method. The topology optimization is performed numerically with the simulation software ANSYS. The additive materials applied are a stainless martensitic chrome-nickel steel (AISI 630) and an aluminum-silicon alloy (EN AC-43000). First, strength-relevant material characteristics are determined experimentally. The effects of different hardening processes on the material characteristics are predicted. These material properties are required for the parameterization of the clamping system simulation model. The modelling approach is described in the following. The simulation results of the non-optimized clamping system serve as a reference for evaluating the properties of the optimized system. The simulation model is then used to perform a mass-based topology optimization of four components of the clamping system with high moments of inertia. The components are evaluated simulatively with regard to their yield strength. As a result of the topology optimization, it is found that the moments of inertia of the components are reduced by up to 72%. Due to the functional, lightweight design of the clamping system, significant reductions in machining and non-productive time of up to 19% are possible.
KW - Additive manufacturing
KW - Lathe clamping system
KW - Material testing
KW - Topology optimization
UR - http://www.scopus.com/inward/record.url?scp=85109218124&partnerID=8YFLogxK
M3 - Conference contribution
AN - SCOPUS:85109218124
SP - 499
EP - 502
BT - Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology
A2 - Leach, R. K.
A2 - Nisbet, C.
A2 - Phillips, D.
T2 - 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021
Y2 - 7 June 2021 through 10 June 2021
ER -