2012 11-15-high-value-manufacturing-sirris-gravet
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TRANSCRIPT
le centre collectif de l’industrie technologique belge
High Value Manufacturing
L’allègement par les techniques additives Une nouvelle manière de concevoir
Denis Gravet Le 15-11-2012
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Additive Manufacturing
- No chips - Freeforms - Complex shapes - Internal shapes - Customization - Materials range - Graded materials
- Lightweight - Internal geometries - Multi-functional - Porosities
High Value Manufacturing
Good opportunity to change the
World by
Accelerate innovation Redesign
New concepts
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Denis Gravet Le 15-11-2012
High Value Manufacturing Why reduce weight ? - less buiding time
- less waste during production (no chips) - less energy during production - less energy during transport - less energy during component using - reduce cost - Carbon footprint ? (Interreg FRED)
Vanguardist sectors
- Aeronautic - Spatial - Automotive - …
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Denis Gravet Le 15-11-2012
High Value Manufacturing How reduce weight ?
Functionalities
Multi-functionality
3D lattice structures
Porosities
Internal freeforms
Topology optimization
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Denis Gravet Le 15-11-2012
High Value Manufacturing
p using: 400b p test: 600b p rupture PM: 1.535b
Pressure resistance Functionalities
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Mass: 1.33kg at 0.8kg) Reduction of 38%
Volume: 171 cm³ at 91 cm³ Reduction of 47%
External size: similar
Pressure resistance OK
Cost 1 unit PM: 450€ (similar conventional) Cost 150 units PM: 43€/unit
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Multi-functionality
Simplification Cooling tube removed and integrated Support integrated Rings and braces removed 12 components 1 part
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Name/Description Part volume Relative Full cube 27.00 cm³ 100 % Circular profile 4.37 cm³ 16 % Spherical 2.75 cm³ 10 % Honeycomb 3.74 cm³ 14 % Double honeycomb 3.25 cm³ 12 % Reduced honeycomb 1.93 cm³ 7 %
Circular profil Honeycomb Spherical
Reduced honeycomb
Double honeycomb 3D lattice structures
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Denis Gravet Le 15-11-2012
High Value Manufacturing
3D lattice structures
Courtesy of OS Orthopedic Services GmbH / inno-shape GmbH
EBM - Oak Ridge National Lab
[Sirris ADD]
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Denis Gravet Le 15-11-2012
High Value Manufacturing Weight reduction with minimal strength reduction Biomedical implants: bone regeneration Graded structures Shock damping Vibration reduction Filtration
Laser Cusing
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Manifolds
Weight Volume Pressure drops Cost Pressure resistance
Internal freeforms
Functionalities
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Volume: 2.900 cm³ Mass: 19.2 kg External size: 210 x 210 x 70mm
Volume: 244 cm³ Mass: 1.2 kg External size: 85 x 85 x 38mm
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Denis Gravet Le 15-11-2012
High Value Manufacturing Pressure drops:
- Very important reduction of pressure drops and also good pressure resistance
3,25b
0,25b
13x
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Denis Gravet Le 15-11-2012
High Value Manufacturing Influence of roughness on pressure drops:
Negligeable regarding previous result and cost of polishing.
0,25b
0,32b
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Mass: 19.2kg at 1.2kg Reduction of 94%
Volume: 2900 cm³ at 244 cm³ Reduction of 92%
External size: much less (210mm => 85mm) Pressure resistance: OK Pressure drops: 3,25 at 0,32b Reduction of 90%
Cost 1 unit PM: 750€ at 538€ Reduction of 28%
Cost 112 units PM: 78€/unit + milling
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Denis Gravet Le 15-11-2012
High Value Manufacturing Internal freeforms
Functionalities
134 drillings
Rounded channels Changing diameters Same functionalities
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Denis Gravet Le 15-11-2012
High Value Manufacturing Pressure drops:
- Very importante reducing of pressure drops
1,4b
0,3b
4,7x
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Mass: 55kg at 20kg Reduction of 63,6%
Volume: 2334 cm³ External size: 265 x 200 x 165mm => 240 x 200 x 150 mm
Pressure resistance: OK Pressure drops: 1,68 at 0,37b Reduction of 78%
Cost 1 unit PM: 2500€ at 3122€ + milling increase of >25%
Cost 6 units PM: 2500€/unit at 2376€ + milling (similar)
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Cooling channels Reduction of cycle time 15% up to 40% (Hipermoulding) Reduction of the energy consumption Improvement of the durability of moulds Improvement of the efficiency of cooling (no warping, good filling…) Carbon foot print
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Complex geometries for multi functionality
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Denis Gravet Le 15-11-2012
High Value Manufacturing Topology optimization (Topol-Samcef)
• Use material only where is needed • Definition of the free space • Define maximum volume • Set of loads • Maximize stiffness
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Free space and set of loads
% volume and max. stiffness
FEM calcul
Design
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Efforts repartition
STL file Smoothing or redesign based on the STL geometry
Free space definition
FEM calcul
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Al
CF PA
AlSi12
Weight reduction: 530g 392g (-26%) 7 components 2 components 3 materials 1 material (1 technology)
Carbon foot print
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Topology Optimisation of a Lever (Images courtesy of JCB)
EADS
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Denis Gravet Le 15-11-2012
High Value Manufacturing
EOS
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Batsheba Grossman
Wim Delvoye / 3DP metal SIRRIS Artistic
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Denis Gravet Le 15-11-2012
High Value Manufacturing Jewelry
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Denis Gravet Le 15-11-2012
High Value Manufacturing Fashion
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Steel part (Concept Laser)
Technical
LayerWise
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Medical
LayerWise
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Added Values
Reduction of assembly and millings Simplification (nbre of components)
Reduction of pressure drops Improvement of stiffness
Reduction of volumes Material optimization Reduction of weigth
Freedom for design Customization Global cost
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Thanks for your attention
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Denis Gravet Le 15-11-2012
High Value Manufacturing
Bruno Verlee Porosities