Skip to main content
Top

2017 | OriginalPaper | Chapter

Improvement of Sustainability Through the Application of Topology Optimization in the Additive Manufacturing of a Brake Mount

Authors : Stefan Junk, Claus Fleig, Björn Fink

Published in: Sustainable Design and Manufacturing 2017

Publisher: Springer International Publishing

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

In recent years, the additive manufacturing processes have rapidly developed. The additive manufacturing processes currently present a high-performance alternative to conventional manufacturing methods. In particular, they offer the opportunity of previously hardly imaginable design freedom, i.e. the implementation of complex forms and geometries. This capability can, for example, be applied in the development of especially light but still loadable components in automotive engineering. In addition, waste material is seldom produced in additive manufacturing which benefits a sustainable production of building components. Until now, this design freedom was barely used in the construction of technical components and products because, in doing so, both specific design guidelines for additive manufacturing and complex strength calculations must be simultaneously observed. Yet in order to fully take advantage of the additive manufacturing potential, the method of topology optimization, based on FEM simulation, suggests itself. It is with this method that components that are precisely matched and are especially light, thereby also resource-saving, can be produced. Current literature research indicates that this method is used in automotive manufacturing for reducing weight and improving the stability of both individual parts and assembly units. This contribution will study how this development method can be applied in the example of a brake mount from an experimental vehicle. In this, the conventional design is improved by means of a simulation tool for topology optimization in various steps. In an additional processing step, the smoothing of the thus developed component occurs. Finally, the component is generatively manufactured by means of selective laser melting technology. Models are manufactured using binder jetting for the demonstration of the process. It will also be determined how this weight reduction affects the CO2 emissions of a vehicle in use.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Springer Professional "Wirtschaft"

Online-Abonnement

Mit Springer Professional "Wirtschaft" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 340 Zeitschriften

aus folgenden Fachgebieten:

  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Versicherung + Risiko




Jetzt Wissensvorsprung sichern!

Literature
1.
go back to reference Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer, New York (2014) Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer, New York (2014)
2.
go back to reference Wohlers, T.: Wohlers Report - Additive Manufacturing and 3D Printing State of the Industry Annual Worldwide Progress Report. Wohlers Associates Inc., Fort Collins (2014) Wohlers, T.: Wohlers Report - Additive Manufacturing and 3D Printing State of the Industry Annual Worldwide Progress Report. Wohlers Associates Inc., Fort Collins (2014)
3.
go back to reference Junk, S., Sämann-Sun, J., Niederhöfer, M.: Application of 3D printing for the rapid tooling of thermoforming moulds. In: Srichand, H., Lin, L. (eds.) Proceedings of the 36th International MATADOR Conference, pp. 369–372, Springer, London (2010) Junk, S., Sämann-Sun, J., Niederhöfer, M.: Application of 3D printing for the rapid tooling of thermoforming moulds. In: Srichand, H., Lin, L. (eds.) Proceedings of the 36th International MATADOR Conference, pp. 369–372, Springer, London (2010)
4.
go back to reference Yoon, H.-S., Lee, J.-Y., Kim, H.-S., Kim, M.-S., Kim, E.-S., Shin, Y.-J., Chu, W.-S., Ahn, S.-H.: A comparison of energy consumption in bulk forming, subtractive, and additive processes review and case study. Int. J. Precis. Eng. Manuf. Green Technol. 1(3), 261–279 (2014)CrossRef Yoon, H.-S., Lee, J.-Y., Kim, H.-S., Kim, M.-S., Kim, E.-S., Shin, Y.-J., Chu, W.-S., Ahn, S.-H.: A comparison of energy consumption in bulk forming, subtractive, and additive processes review and case study. Int. J. Precis. Eng. Manuf. Green Technol. 1(3), 261–279 (2014)CrossRef
5.
go back to reference Campbell, I., Bourell, D., Gibson, I.: Additive manufacturing: rapid prototyping comes of age. Rapid Prototyping J. 18(4), 255–258 (2012)CrossRef Campbell, I., Bourell, D., Gibson, I.: Additive manufacturing: rapid prototyping comes of age. Rapid Prototyping J. 18(4), 255–258 (2012)CrossRef
6.
go back to reference Mueller, B., Hund, R., Malek, R., Gebauer, M., Polster, S., Kotzian, M., Neugebauer, R.: Added value in tooling for sheet metal forming through additive manufacturing. In: International Conference on Competitive Manufacturing, pp. 1–7 (2013) Mueller, B., Hund, R., Malek, R., Gebauer, M., Polster, S., Kotzian, M., Neugebauer, R.: Added value in tooling for sheet metal forming through additive manufacturing. In: International Conference on Competitive Manufacturing, pp. 1–7 (2013)
7.
go back to reference Frisch, M., Glenk, C., Dörnhöfer, A., Rieg, F.: Topology optimization for small and medium-sized enterprises - from experience-based construction to the use of topology optimization for the product development process. ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb 111(5), 243–246 (2016) Frisch, M., Glenk, C., Dörnhöfer, A., Rieg, F.: Topology optimization for small and medium-sized enterprises - from experience-based construction to the use of topology optimization for the product development process. ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb 111(5), 243–246 (2016)
8.
go back to reference Pacurar, R., Pacurar, A.T.: Topology optimization of an airplane component to be made by selective laser melting technology, Modern Technologies in Manufacturing, MTeM. In: International Conference on Modern Technologies in Manufacturing (2015). Appl. Mech. Mater. 808, 181–186. Trans Tech Publication, Zürich Pacurar, R., Pacurar, A.T.: Topology optimization of an airplane component to be made by selective laser melting technology, Modern Technologies in Manufacturing, MTeM. In: International Conference on Modern Technologies in Manufacturing (2015). Appl. Mech. Mater. 808, 181–186. Trans Tech Publication, Zürich
9.
go back to reference Oliveira, J., Teixeira, P., Lobo, G., Duarte, J., Reis, A.: Topology optimization of a car seat frame, the current State-of-the-Art on material forming. In: 16th International ESAFORM Conference on Material Forming, ESAFORM (2013) Oliveira, J., Teixeira, P., Lobo, G., Duarte, J., Reis, A.: Topology optimization of a car seat frame, the current State-of-the-Art on material forming. In: 16th International ESAFORM Conference on Material Forming, ESAFORM (2013)
10.
go back to reference Guangyao, L., Fengxiang, X., Xiaodong, H., Guangyong, S.: Topology optimization of an automotive tailor-welded blank door. Trans. ASME J. Mech. Des. 137(5), 1–8 (2015) Guangyao, L., Fengxiang, X., Xiaodong, H., Guangyong, S.: Topology optimization of an automotive tailor-welded blank door. Trans. ASME J. Mech. Des. 137(5), 1–8 (2015)
11.
go back to reference Chen, D., Heyer, S., Ibbotson, S., Salonitis, K., Steingrímsson, J.G., Thiede, S.: Direct digital manufacturing: definition. Evol. Sustain. Implications J. Cleaner Prod. 107, 615–625 (2015)CrossRef Chen, D., Heyer, S., Ibbotson, S., Salonitis, K., Steingrímsson, J.G., Thiede, S.: Direct digital manufacturing: definition. Evol. Sustain. Implications J. Cleaner Prod. 107, 615–625 (2015)CrossRef
12.
go back to reference Stroobants, J., Campestrini, P.: Component optimisation through simulation driven design. Topology & topography optimization. In: Proceedings of 3rd Commercial Vehicle Technology Symposium on Commercial Vehicle Technology, CVT (2014) Stroobants, J., Campestrini, P.: Component optimisation through simulation driven design. Topology & topography optimization. In: Proceedings of 3rd Commercial Vehicle Technology Symposium on Commercial Vehicle Technology, CVT (2014)
13.
go back to reference Li, C., Kim, I.Y.: Topology, size and shape optimization of an automotive cross car beam. Proc. Inst. Mech. Eng. Part D J. Automobile Eng. 229(10), 1361–1378 (2015)CrossRef Li, C., Kim, I.Y.: Topology, size and shape optimization of an automotive cross car beam. Proc. Inst. Mech. Eng. Part D J. Automobile Eng. 229(10), 1361–1378 (2015)CrossRef
14.
go back to reference Salonitis, K.: Design for additive manufacturing based on the axiomatic design method. Int. J. Adv. Manuf. Technol. 87, 989–996 (2016)CrossRef Salonitis, K.: Design for additive manufacturing based on the axiomatic design method. Int. J. Adv. Manuf. Technol. 87, 989–996 (2016)CrossRef
15.
go back to reference Salonitis, K., Al Zarban, S.: Redesign optimization for manufacturing using additive layer techniques. Procedia CIRP 36, 193–198 (2015)CrossRef Salonitis, K., Al Zarban, S.: Redesign optimization for manufacturing using additive layer techniques. Procedia CIRP 36, 193–198 (2015)CrossRef
16.
go back to reference Madenci, E., Guven, I.: The Finite Element Method and Applications in Engineering Using ANSYS®. Springer, New York (2016) Madenci, E., Guven, I.: The Finite Element Method and Applications in Engineering Using ANSYS®. Springer, New York (2016)
17.
go back to reference Rozvany, G., Lewiński, T. (eds.): Topology Optimization in Structural and Continuum Mechanics. Springer, Heidelberg (2013)MATH Rozvany, G., Lewiński, T. (eds.): Topology Optimization in Structural and Continuum Mechanics. Springer, Heidelberg (2013)MATH
18.
go back to reference Lachmayer, R., Lippert, R.B., Fahlbusch, T. (eds.): 3D-Druck beleuchtet - Additive Manufacturing auf dem Weg in die Anwendung. Springer, Heidelberg (2016) Lachmayer, R., Lippert, R.B., Fahlbusch, T. (eds.): 3D-Druck beleuchtet - Additive Manufacturing auf dem Weg in die Anwendung. Springer, Heidelberg (2016)
19.
go back to reference Cheah, L., Heywood, J., Kirchain, R.: The Energy of Impact US Passenger Vehicle Fuel Economy Standards. MIT, Cambridge (2008) Cheah, L., Heywood, J., Kirchain, R.: The Energy of Impact US Passenger Vehicle Fuel Economy Standards. MIT, Cambridge (2008)
20.
go back to reference Kenny, T., Gray, N.F.: Comparative performance of six carbon footprint models for use in Ireland. Environ. Impact Assess. Rev. 29(1), 1–6 (2009)CrossRef Kenny, T., Gray, N.F.: Comparative performance of six carbon footprint models for use in Ireland. Environ. Impact Assess. Rev. 29(1), 1–6 (2009)CrossRef
Metadata
Title
Improvement of Sustainability Through the Application of Topology Optimization in the Additive Manufacturing of a Brake Mount
Authors
Stefan Junk
Claus Fleig
Björn Fink
Copyright Year
2017
DOI
https://doi.org/10.1007/978-3-319-57078-5_15

Premium Partner