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Cooperation Altair – EOS – EADS-IW
Topology design of a metallic loadintroduction bracket manufactured by ALM
Wolfgang MACHUNZE – EADS Innovation Works
Thomas LEHMANN – Altair
Peter HEIN– EOS
23. April 2013
ABSTRACT
INTRODUCTION
• Bracket for High lift device
• EOS: ALM Process
SCALMALLOY®
• Sc-modified & tailored AlMg-alloys
• Strength investigations
TOPOLOGY OPTIMIZATION
• Model
• Process chain
TOPOLOGY RESULT – POST-TREATMENT
• STL format
• Support structure
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INTRODUCTIONBracket for High lift device
ALM bracket
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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:
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INTRODUCTIONProblem definition
• Determine an ALM design for a metallic drive strut bracket considering all static andmanufacturing constraints
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INTRODUCTIONEOS: ALM Process
ALM bracket
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INTRODUCTIONEOS: ALM Process
Source: EOSAdditive Manufacturing – functional principle
Direct – generative – resource efficient
From a 3D CADmodel…
… to completeparts
Application ofpowder
Exposure byLaser
Lowering ofplatform
Re-application ofpowder
Exposure byLaser
Works for plastics and metals
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Source: EOS
INTRODUCTIONEOS: ALM Process
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Source: EOS
INTRODUCTIONEOS: ALM Process
Key differentiation criteria for laser sintering
Freedom of design Cost advantage CustomizationOrganization
Time to market
Lightweight
Static: weight of parts
Dynamic: moving,accelerated parts
Complex components
E.g. alternativestructures of heatexchangers
Integratedfunctionality
Embeddedfunctionality withoutassembly
Individualized parts
Customer specificadaptations
Cost efficient smallseries up to'lot size one'
Rapid prototyping
Fast feasibilityfeedback of virtualmodels
Haptic feedback
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Source: EOS
INTRODUCTIONEOS: ALM Process – Manufacturing constraints
Design 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 treatment
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SCALMALLOY®ALM bracket
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Scalmalloy® ScalmalloyRP® Very
high strength Al-profiles High strength ALM AlMgSc alloys
ScalmalloySC®High performance sheet material
for 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 strength
increment is reported for higher Sc contents
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TOPOLOGY OPTIMIZATIONALM bracket
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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:
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Topology design of metallic ALM bracket
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TOPOLOGY OPTIMIZATIONOptimization parameter
Objective:
• Min. weighted compliance
Constraints:
• VolFrac drive strut bracket: 0.4 (variable)
• Element force tension screw > 0
• Element force compression screw < 0
Topology optimization:
• MinDim: 8 mm (variable)
• Stress constraint: 500 MPa (AlMgSc)
• 1-plane symmetry
• Extrusion direction derived from first initial optimization step
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TOPOLOGY OPTIMIZATIONProcess chain
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Non design room for bushing
Topology result Iso 0.85
Which is the lightest ISO design?
Automated routine to derivelightest ISO design which fits thedefined stress / strain / …constraints
Reanalysis of topologyresult Iso 0.85 feasibledesign
TOPOLOGY OPTIMIZATIONFeasible Iso results
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Design and sizing of Krüger flap
4/25/2013
ISO 40 MPa ISO 30 MPa
ISO 10 MPaISO 20 MPa
TOPOLOGY OPTIMIZATIONFeasible Iso results
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Design and sizing of Krüger flap
4/25/2013
Iso 0.85 Iso 0.65
107 g 129 g
+ lower weight + minor support structure
TOPOLOGY RESULT – POST-TREATMENT
ALM bracket
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TOPOLOGY RESULT – POST-TREATMENTSTL smoothing with Hypermesh
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1. OSSmooth:Following settings:
2. AutoMeshFollowing settings:
3. Export STL file
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 sufficient
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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 experience
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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 process
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Support necessary No support necessary
Gothic structures
TOPOLOGY RESULTManufactured ALM load introduction bracket
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Thank you for you attention!
Wolfgang Machunze
+49 (0) 89-607 29580
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Thomas Lehmann
+49 (0) 7031-6208141
Peter Hein
+49 (0) 89-893 362230
