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Case Studies for Additive Manufacturing Designs
August 10, 2017Youngstown, OH
Bianca LankfordMechanical Engineer
SME SMART Manufacturing Seminar Series
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Agenda
• Why AM?
• Key Enablers
• Case Study Examples
• Summary
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Why use AM?
• Minimize production times
• Cost savings
• Lead time savings
• Rapid product development
• Reduce manufacturing steps
• Great for low-quantity builds
• Complexity is free!
AM can reduce cost and lead time for production assemblies
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The AM Process: Art to Part
Engineers design AM parts
Rigorous analysis and/or test to reduce risk
Program adoption (on PL)
Qualification and certification processes
Procurement processes
AM parts in production
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Use Cases for AM
• Brackets
• Ducts and plenums
• Coldplates
• Antennas
• Test Fixtures
• Rapid Prototypes
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AM Enables Cost and Schedule Savings
• When properly utilized, Additive Manufacturing is a cost and schedule saver for:
• Rapid Build Cycle• Reduce Parts Count• Low Cost Iterations• Complex & Affordable• Design Freedom• Convenience• Schedule Compression• Light Weight
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Develop fundamental capabilitiesMetal AM (Ti-6Al-4V, AlSi10Mg, etc.)Polymer Ongoing: Supply Chain partnershipsIdentify SMEs and train employees
Expand capabilitiesFurther develop SMEs in AMEstablish Sector COE’s
Factory of the FutureHybrid manufacturing capabilityInterconnected machines & automated handling using Co-Bots
2014-2019
2020-2023
2024 +
We are invested in the future of AM
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Northrop Grumman AM Consortium
• Collaborative, multidisciplinary team that shares latest AM test data, resources and best practices across Northrop Grumman Corporation.
• Every sector is involved – Aerospace Systems, Mission Systems and Technology Services
• Annual meetings and monthly working groups keep everyone in the loop
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Key Enablers for NG Additive Manufacturing
“Iterate to Excellence”
• Engineering and Manufacturing expertise
• AM Consortium collaboration
• In-house capabilities
• Solid supply base partners
• University collaboration
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Case Study 1: G/ATOR Cable Clamp
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What is G/ATOR?AN/TPS-80 Ground Air Task Oriented Radar
• A new S Band multi-mission radar Northrop Grumman has developed for the U.S. Marine Corps.
• The first multi mission ground radar developed by the U.S. Department of Defense:
– An unprecedented combination of operational capabilities
• Multi-threat capable– Detects and tracks a broad range of airborne
threats– Fixed wing & rotary wing aircraft, Unmanned
Autonomous Systems, cruise missiles, rockets/artillery/mortars
– Provides a precise, real time, actionable, integrated air picture, even in complex operational scenarios.
• Easily deployed due to expeditionary design (lightweight and mobile)
• Largest radar program in U.S. Marine Corps history:• Total program value exceeds $2B– DOD investment to date exceeds $550M
• The primary radar that the Marine Corps will utilize worldwide for the next 30+ years.
An unprecedented combination of Operational Capabilities… APPROVED FOR PUBLIC RELEASE
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G/ATOR cable clamps
• Design challenges Robust AM solution
• We iterate to excellence
• Reduce risk
• 72% cost savings over machined Delrin (subtractive mfg)
• Lessons learnedG/ATOR
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G/ATOR Cable Clamps – Risk Mitigation
The work done to burn down the risk includes the following:
• Multiple iterations of part builds with different materials, different sizes, and different machines to find an optimized design to meet requirements• Mechanical fit checks using hardline cables to ensure cable clamping and mechanical integrity of the design (functionality maintained, parts don’t
break, etc) is optimized• RF analysis to ensure the parts do not over clamp the RF hardline cables and that the cables will still meet expected performance• Temperature cycle testing (-40 °C to +71 °C)• Creep testing and comparison to machined Delrin clamps• Detailed tolerance studies to ensure same functionality to machined Delrin clamps is achieved• Increased the size of the washers that secure the parts in place to ensure sufficient bearing area to overcome hole deformities• Created a structural FEM of the cable. Used the FEM to determine the max clamping load that keeps the RF characteristic impedance of the
cable within tolerance limits (50 +/- 5 ohms)
VSWR (dB)For various compression amounts
From an email June 2nd announcing AM Insertion into G/ATOR
Significant Risk Reduction Builds, Testing & Analyses Completed!APPROVED FOR PUBLIC RELEASE
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.086” Ø
.112” Ø
.136” Ø.086” Ø
.112” Ø
.136” Ø.112” Ø.164” Ø
#2= .086” Ø#4= .112” Ø #6= .138” Ø #8= .164” Ø
G/ATOR Cable Clamps with #2, #4, #6 & #8 Screws inserted
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DoE Summary
• Test Plate Designed to Simulate Production Installation of G/ATOR AM Cable Clamps
– Used Production Screws and Standoffs– Replicated Production Configurations
• Tested 34 Production Parts in Total– 19 Tested on Standoffs, 15 Tested on Flat Plate– Torque Applied Incrementally from 1 to 7 in-lbs.– Maximum Survivable Torque and Failure Torque were Recorded
Sample # PNPlanar/Mounting
Hole?Flat/Standoff?
Max Survivable Torque (in-lbs)
Failure Torque (in-lbs)
Date Tested
Parts From…
Notes
Mounting Standoff 3 4 1/30/2017 Kitted Marked 8--one we tested in RR's officePlanar Standoff 5 6 1/30/2017 Kitted
Mounting Flat 6 7 1/30/2017 KittedPlanar Flat 9 N/A 1/30/2017 Kitted
3 H46 Planar Flat 9 N/A 1/30/2017 Kitted Screw broke at 10 in/lbs4 H45 Planar Standoff 7 N/A 2/2/2017 Stores5 H45 Planar Flat 7 N/A 2/2/2017 Stores6 H45 Planar Standoff 7 N/A 2/2/2017 Stores7 H45 Planar Flat 7 N/A 2/2/2017 Stores8 H45 Planar Standoff 7 N/A 2/2/2017 Stores9 H45 Planar Flat 7 N/A 2/2/2017 Stores
10 H45 Planar Standoff 7 N/A 2/2/2017 Stores11 H45 Planar Flat 7 N/A 2/2/2017 Stores12 H45 Planar Standoff 7 N/A 2/2/2017 Stores13 H45 Planar Flat 7 N/A 2/2/2017 Stores14 H45 Planar Standoff 7 N/A 2/2/2017 Stores15 H44 Planar Flat 7 N/A 2/2/2017 Stores Being tested in timed torque test16 H44 Planar Standoff 7 N/A 2/2/2017 Stores17 H44 Planar Flat 7 N/A 2/2/2017 Stores18 H44 Planar Standoff 7 N/A 2/2/2017 Stores19 H44 Planar Standoff 7 N/A 2/2/2017 Stores Being tested in timed torque test20 H46 Planar Flat 7 N/A 2/2/2017 Stores21 H46 Planar Standoff 7 N/A 2/2/2017 Stores22 H46 Planar Flat 7 N/A 2/2/2017 Stores23 H46 Planar Standoff 7 N/A 2/2/2017 Stores24 H46 Planar Standoff 7 N/A 2/2/2017 Stores
Mounting Flat 4 5 2/2/2017 StoresPlanar Flat 7 N/A 2/2/2017 Stores
Mounting Standoff 4 5 2/2/2017 Stores Left mounting hole brokePlanar Standoff 7 N/A 2/2/2017 Stores
Mounting Flat 4 5 2/2/2017 Stores Left mounting hole broke at 5, Right mounting hole broke at 7Planar Flat 7 N/A 2/2/2017 Stores
Mounting Standoff 3 4 2/2/2017 Stores Left mounting hole broke, small crack starting at 4, full crack going to 5 in-lbsPlanar Standoff 6 7 2/2/2017 Stores
29 H44 Planar Standoff 7 N/A 2/3/2017 Kitted30 H45 Planar Standoff 7 N/A 2/3/2017 Kitted31 H46 Planar Standoff 7 N/A 2/6/2017 Kitted
Mounting Standoff 4 5 2/6/2017 Kitted Both mounting holes brokePlanar Standoff 6 7 2/6/2017 Kitted Broke between mounting holes
33 H44 Planar Flat 7 N/A 2/6/2017 Kitted34 H45 Planar Flat 7 N/A 2/6/2017 Kitted
32 H47
27 H47
28 H47
H47
H47
1
2
26 H47
25 H47
Test Results Support Analyses Predictions of Added Stress from Standoffs29
Case Study 2: G/ATOR Air Duct
ASE Air Ducts
• Designed multiple prototypes
• Re-designed for AM– 3 pieces into 1
• More lightweight
• 60% cost savings ($26k to $10k)
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PEKK Insertion into production: ASE Air Ducts
Northrop Grumman Corporation Private / Proprietary Level 1
Air Duct
EMI Filter
Air Duct
AM Air Duct
EMI Filter
OR
Baseline Design: Brazed Aluminum
• $26K per air duct pair
• Two ducts, One EMI Filter/One Bracket
AM Design: PEKK- Carbon Filled
• $10K per air duct pair
• Bracket Removed
• One duct & one external EMI Filter
AM Design: PEKK- Carbon Filled
• $9.6K per air duct pair
• Bracket removed
• One duct: Plated/Painted
Integral AM air duct
Bracket
NoBracket
AM DESIGN OPTIONS
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Case Study 3: Aluminum Coldplate
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Existing Design vs. AM Design: Models
Finned passages printed “in” rails
Heat Generating Card
Wedge Clamp
Cold Plate Rail
Traditional location for brazed-finned cooling
passages
FRONT VIEW
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Conclusion
• We tackle complex problems with Iterate to Excellence as our motto
• Creating AM solutions for:– On the ground– In the air– Undersea / on the sea– In space
• Exciting future ahead!
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Backup Content
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G/ATOR – One Material Solution Doing the Job of Multiple Radars for Maximum Operational Flexibility
Air Defense/SHORAD Air Surveillance
Counterfire Target Acquisition Air Traffic Control
Unprecedented Multi-Mission Capabilities in a Single Radar
Possible Future Mission:TBM Detection/Tracking
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Northrop Grumman Mission Systems
Is a trusted provider of mission-enabling solutions for global security
Is committed to unmatched performance excellence in C4ISR and cyber solutions
Has a wide portfolio of secure, affordable, integrated, and multi-domain systems and
technologies
Mission-Enabling Solutions39
Mission Systems Sector Today
*IS and ES Approximation
• Leading global provider of secure software-defined, hardware-enabled mission systems
• $10.7* billion sales in 2015• 26,000 employees• In all 50 U.S. states and 21
countries• Pioneering capabilities in:
– Full-Spectrum Cyber– End-to-End & Integrated C4ISR– Innovative Integrated Solutions– Mission Effectiveness from Undersea
to Space and Cyberspace
Mission-Enabling Solutions40
Mission SystemsFrom Undersea to Outer space
Advanced Concepts &
Technologies
• Cyber & Advanced Processing
• Surveillance & Targeting Sensors
• Multifunction Systems• Integrated Solutions• Transformational
Computing• Advanced
Microelectronics
• Restricted Programs• RF Systems• EO/IR Solutions• Ground Enterprise• SSA & Space
Operations• Environmental Solutions• Integrated Solutions• Space C2• Exploitation Processing• OPIR/SIGINT/GEOINT
Cyber and Intelligence
Mission Solutions Division
Land & Avionics C4ISR Division
Missile Defenseand Protective
Systems Division
Navigation and Maritime Systems
Division
Space ISR Systems Division
• Integrated Aircraft Survivability Equipment
• Multi-Spectral Electronic Warfare Systems
• Integrated Avionics Suites
• C2 ERP Systems• Global Mission Solutions
Airborne C4ISR Systems Division
• Fire Control Systems• Surveillance Systems• Electro Optical Systems• Targeting Systems• Communications• SIGINT Systems• Air C2 & Airborne ISR• Electronic Attack• Targeting and Weapon
Planning
• Propulsion & Power Systems
• Cold Launch• Maritime Electronic
Warfare & Radars• Maritime C2• Machinery Control
Systems• Undersea Sensors &
Solutions• Navigation &
Positioning Systems• International Navigation
& Pointing Solutions
• Intelligence Acquisition & Analytics
• Cyber Resiliency• Cyber Defense• Cyber/Non-Kinetic
Operations• Intelligence
Enterprise
• C2 for Missile Defense, IAMD, Nuclear Systems and Land Forces
• Strategic Ground Systems
• BMDS Integration, Testing Training, and Readiness Support
• Integrated Fires• Civil Aviation Planning
and ATC• Civil C2 for Emergency
Responders41
AM Virtual Collaboration
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Abstract and Bio
Abstract
• Recent advancements in 3D printing technologies have opened up a new world for engineering design. Custom parts are being designed faster than ever, and with decreased lead times from their subtractively manufactured counterparts. Additive Manufacturing (AM) also supports rapid iteration of parts, reducing the product development life cycle time and cost. AM is especially popular with low-quantity builds, due to the drastic reduction of casting molds, fixtures, machining time and manufacturing steps. All of these advancements provide a unique opportunity for Northrop Grumman Mission Systems to incorporate AM parts into our products and manufacturing processes. This presentation will include case studies of 3D printed parts and examples of the materials utilized.
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Speaker Bio
Bianca Lankford is a mechanical engineer at Northrop Grumman Mission Systems in Baltimore, MD. She is a thermal analyst, Additive Manufacturing SME and manager of the Technology Underground innovation lab. In addition, Bianca leads the Design for Additive Manufacturing (DFAM) team and co-chairs the AM Polymers working group. She has published 7 papers on Additive Manufacturing at Northrop Grumman and received multiple IP awards for her contribution to the technology.
Bianca lives in Baltimore, MD with her husband, James, and their puppy, Daisy.
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