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Panel Discussion

Application Aerospace

One of the hottest, most innovative and also most demanding drivers in the usage of Additive Manufacturing is Aerospace. Weight reduction and complex geometries are only parts of the puzzle. The panel discussion deals with the latest developments.

1 December 2021

Speakers

Dr. Andreas Vlahinos, CEO of Advanced Engineering Solutions
Andreas has concentrated on DfAM, Computer Aided Innovation, Generative Design, Lattice Structures, Simple Solutions to Complex Problems. He has been instrumental in rapid product development through the implementation of Computer Aided Engineering for several Government agencies such as NASA, NREL, SANDIA, DOE, NCDMM and US Army Aviation & Missile Command and several industry partners such as SpaceX, General Dynamics, United Launch Alliance, NAVISTAR Defense, etc. He has been Professor of structural engineering at the University of Colorado.  Several times he received the Professor of the Year Award.  He has received the R&D 100 award and several patents. He received his Ph.D. in Engineering Science and Mechanics from Georgia Institute of Technology. Finally, he is regularly invited as a keynote speaker on a variety of subjects (Generative Design,
Innovation, DFSS, DfAM, IoT) in international conferences.

Christoph Riepl, Analysis Engineer PRIME aerostructures GmbH
The focus of PRIME aerostructures GmbH within 3dAeroTiP was the redesign of an aerospace component and the simulation of the AM manufacturing process, all within the 3DEXPERIENCE platform from Dassault Systèmes. For the redesign of the component, a functional generative design approach with topology optimization was used. The goal of the optimization was to reduce the weight by at least 15% while maintaining the same stiffness. The result of the optimization was a bionic shape which was then used to create the new innovative design. The resulting parametric design was further refined by parameter optimization using the material database created in the project and was adapted to the requirements of the AM-process L-PBF. The final design was then validated using the critical static and fatigue load cases to show sufficient strength and stiffness of the component. Before manufacturing the first demonstrators of the new design a simulation of the AM-process was carried out. For this purpose, a thermal mechanical simulation model was built and calibrated with a cantilever beam setup. Several test builds and iterations of the simulation were carried out to achieve good results of residual stresses and deformations. Because of the large size of the component, the thermal mechanical simulation was reduced to a mechanical simulation using the eigenstrain-method. The results of these simulations were used to find the best build orientation, optimize the support strategy, and to adjust some critical regions of the component. The predicted residual stresses have been incorporated in the static validation of the design and the predicted deformations were used to define the material allowances necessary for the mechanical processing that followed the AM fabrication. All these design and simulation tasks were performed in the software platform 3DEXPERIENCE, eliminating all interfaces, greatly reducing the time of the product design cycle, and removing sources of error.

Tags

  • Additive Manufacturing
  • Aviation and Aerospace