Using Axiomatic Design for the Development of Product Configuration Systems

In order to meet a wide range of customer requirements in product development, a high degree of individualization is necessary today, which can be achieved with product configuration systems. Knowledge-based CAD models are a useful tool for implementing such configurators, but they are significantly more complex to develop than conventional parametric CAD models. To master this complexity, this article examines the use of the axiomatic design approach for the development of a configurator for a skip loader. In combination with the parameter space matrix, an application-oriented methodology is derived which is suitable for the development of similar configuration systems

Additive manufacturing of multi-material parts – Design guidelines for manufacturing of 316L/CuCrZr in laser powder bed fusion

Additive manufacturing (AM) can be used to produce multi-material parts in which the material can be varied voxel-wise in all three spatial directions. This means that the paradigm of the homogeneous material can be abandoned and local effects such as heat conduction or damping can be selectively adjusted in the part. Recently, continuous development of machine technology has allowed the production of multi-metal materials in laser powder bed fusion (PBF-LB/MM). Compared to other additive manufacturing processes for multi-material production, this allows greater design freedom and detail accuracy to be realized. However, due to the novel character of multi-material manufacturing in PBF-LB, the process knowledge for successful and reproducible fabrication is currently lacking. This paper focuses on establishing design guidelines for manufacturing the material pairing of stainless steel 316L (1.4404) and copper alloy CuCrZr (CW106C). The article is accompanied by the development of a specific process chain. As a result of this work, design guidelines for multi-material parts are available for the first time, in regard to arrangement, size, overhangs, economy, powder quality and laser scanning

Design Guidelines for Additive Manufactured Particle Dampers: A Review

Recently, additive manufacturing has been used to integrate particle dampers into structural components, particularly by means of laser powder bed fusion (LPBF), in order to significantly reduce component vibrations. The advantage over previous damping mechanisms is that these can be functionally integrated directly into the component during the additive manufacturing process by leaving unmelted powder in the component. This allows local damping effects to be adjusted and low-vibration lightweight structures to be developed and manufactured. In addition, the damping properties act over a wide frequency range and are insensitive to temperature. Despite the positive damping properties, the use of laser beam melted particle dampers is limited at the present time, since there are not yet sufficient design tools available due to the numerous non-linear influences. This is where the current contribution comes in, by developing design guidelines for laser beam melted particle dampers. The results were finally summarised in a design catalogue and support a suitable design of laser beam melted particle dampers

Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth

Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites

Process-Integrated Lubrication in Sheet Metal Forming

The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising geometries of the lubrication channels and outlet openings are first identified by means of numerical simulation at the example of a demonstrator process. Cylindrical test specimens with the specified channel geometries are additively manufactured and installed in a strip drawing test stand. Additive manufacturing enables the possibility of manufacturing complex channel geometries which cannot be manufactured by conventional methods. A hydraulic metering device for conveying lubricant is connected to the cylindrical test specimens. Thus, hydraulically lubricated strip drawing tests are performed. The tests are evaluated according to the force curves and the fluid mechanical buildup of pressure cushion. The performance of process-integrated lubrication is thus analyzed and evaluated. By means of a coupled forming and SPH simulation, the lubrication channels could be optimally designed. From the practical tests, it could be achieved that the drawing force decreases up to 27% with pressure cushion build up. In this research, a hydraulic lubrication in the area of highest contact normal stresses is the most optimal process parameter regarding friction reduction

Additive manufacturing of multi-material parts – Design guidelines for manufacturing of 316L/CuCrZr in laser powder bed fusion

Additive manufacturing (AM) can be used to produce multi-material parts in which the material can be varied voxel-wise in all three spatial directions. This means that the paradigm of the homogeneous material can be abandoned and local effects such as heat conduction or damping can be selectively adjusted in the part. Recently, continuous development of machine technology has allowed the production of multi-metal materials in laser powder bed fusion (PBF-LB/MM). Compared to other additive manufacturing processes for multi-material production, this allows greater design freedom and detail accuracy to be realized. However, due to the novel character of multi-material manufacturing in PBF-LB, the process knowledge for successful and reproducible fabrication is currently lacking. This paper focuses on establishing design guidelines for manufacturing the material pairing of stainless steel 316L (1.4404) and copper alloy CuCrZr (CW106C). The article is accompanied by the development of a specific process chain. As a result of this work, design guidelines for multi-material parts are available for the first time, in regard to arrangement, size, overhangs, economy, powder quality and laser scanning

Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth

Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites

Process-Integrated Lubrication in Sheet Metal Forming

The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising geometries of the lubrication channels and outlet openings are first identified by means of numerical simulation at the example of a demonstrator process. Cylindrical test specimens with the specified channel geometries are additively manufactured and installed in a strip drawing test stand. Additive manufacturing enables the possibility of manufacturing complex channel geometries which cannot be manufactured by conventional methods. A hydraulic metering device for conveying lubricant is connected to the cylindrical test specimens. Thus, hydraulically lubricated strip drawing tests are performed. The tests are evaluated according to the force curves and the fluid mechanical buildup of pressure cushion. The performance of process-integrated lubrication is thus analyzed and evaluated. By means of a coupled forming and SPH simulation, the lubrication channels could be optimally designed. From the practical tests, it could be achieved that the drawing force decreases up to 27% with pressure cushion build up. In this research, a hydraulic lubrication in the area of highest contact normal stresses is the most optimal process parameter regarding friction reduction

Never Ask for a Lighter Rain but a Stronger Umbrella

In a recent editorial in the journal Nature Sustainability, the editors raised the concern that journal submissions on water studies appear too similar. The gist of the editorial: "too many publications and not enough ideas." In this response, we contest this notion, and point to the numerous new ideas that result from taking a broader view of the water science field. Drawing inspiration from a recently hosted conference geared at transcending traditional disciplinary silos and forging new paradigms for water research, we are, in fact, enthusiastic and optimistic about the ways scientists are investigating political, economic, historical, and cultural intersections toward more just and sustainable human-water relations and ways of knowing