3D Printing introduction + Topology Optimization with Fusion 360 Istanbul – ITÜ Makina Fakültesi Tayfun Süle // April 11th
Tayfun un Süle le Team leader ALM / 3D Printing B.Eng. Aircraft Engineer M.Sc. Composites Since 2011 working for the Heinkel Group Since 2014 responsible for ALM activities 2 …by www.heinkel -group.com
family owned since over 120 1974 Who are we? employees from 20 nations Headquarter in Hamburg, Germany 3 … by www.heinkel-group.com
Who are we? Strategy & Projects Over 100 experts in HR Services all industries 4 … by www.heinkel-group.com
What t are we doing? ng? 5 … by www.heinkel-group.com
Facts ts Established: 2013 Geschultes Personal: 17 Industries: Aerospace Automotive Mechanical Eng. Teamleader Engineering Testing Steel Workshops / Construction Topology Optimization / Static & environmental Construction Testing Fashion Food 6 …by www.heinkel -group.com
Your exper erts s for addit itiv ive e manufac ufactur turing ng Consulting Development Manufacturing Testing • Part Screening • Design / • Prototypes • Static Testing Construction • Serial • Series • Dynamic Testing development • Reverse Engineering • Workshops • Optimization 7 …by www.heinkel -group.com
What t is 3D Printing? ting? • Laying down thin layers of material • Creating of objects from 3D CAD Model https://de.wikipedia.org/wiki/3D-Druck 8 …by www.heinkel -group.com
FDM DM – Fused sed Depo posit sit Moulding lding • Melting Material thru hot nozzle • Material just on locations, where it is needed • Mainly used for Plastics 9 …by www.heinkel -group.com
SLM – Select ectiv ive e Laser r Meltin ing • Material melted with a laser • Mainly used for Metals 10 …by www.heinkel -group.com
Materi rial als • All weldable metals (Steel, Aluminium, Titanium, Gold, …) • Plastics (ABS, PLA, PVA, PET, …) http://www.lboro.ac.uk/microsites/enterprise/e2hs/ • Ceramics • Organics • Food, Glass, … http://www.insidemetaladditivemanufacturing.com 11 …by www.heinkel -group.com
Histo tory ry • Developed in 1983 from Chuck Hall • Main Reason: fast Prototyping • First Patents in 1986 https://www.epo.org/learning-events/european-inventor/finalists/2014/hull_de.html 12 …by www.heinkel -group.com
Industrial use For who is it useful? ful? Home use 13 …by www.heinkel -group.com
Indu dustr stria ial l Use • Manufacturing of small batches • Weight loss for complex parts • Faster manufacturing for complex parts • Integration of new functions • Simplifying complex assemblies • Designs which are not possible with conventional processes http://www.airbusgroup.com/int/en/story-overview/Pioneering-bionic-3D-printing.html 14 …by www.heinkel -group.com
Disadv sadvantages antages of AM • Slow! • Automatization • Quality • High Invest • Materials • Know How • Certification • … Why? 15 …by www.heinkel -group.com
Adv dvantages ntages of AM • Data for manufacturing can be directly used from CAD Systems (Autodesk, CATIA, …) • Small batches staring from lotsize 1 • Reducing of development time • No Tools are needed (Moulds etc) • Geometrical Freedom • Weight • Function • Complex structures EADS Case Study – 3D Printing • Substitution of parts 16 …by www.heinkel -group.com
Complexity for free -> Costs Conventionally Geometr tric ical al Freedo edom Manufacturing Additive Manufacturing Complexity 17 …by www.heinkel -group.com
Findi nding ng the right t Brack ckets ts and Assembli semblies • Total of 5 Parts (2 Milled, 3 Sheet Metal) • Connecting Devices (17) • Total Weight of 239 g 18 …by www.heinkel -group.com
Topo pology logy optimizatio imization 1. Creation of Design space 2. Mark areas which can´t be changed 19 …by www.heinkel -group.com
Result ult of Topolog ology Optim imiza ization tion 3. Understanding the results 4. Creation of CAD Model 5. Analyze 20 …by www.heinkel -group.com
Final al Part Final weight: 53 g Parts: 1 Connecting Devices: 9 21 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Attachments: 2 Force: 100 N Weight: 223 g Next Step: Analyse current stresses – F360 22 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Max Stress: 24.3 Mpa Max Deformation: 0.32 mm Next Step: Creation of Design Space – F360 23 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Creation of Design Space • Extend Space wherever it is possible Next Step: Creation of Boundary Conditions – F360 24 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Creation of Boundary Conditions Next Step: Creation of Loads – F360 25 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Creation of Loads Next Step: Choose of Shape Optimization Goal – F360 26 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Shape Optimization Goal Next Step: TopOpt Example 27 …by www.heinkel -group.com
Topo pology logy Optim imization ation App pp 28 …by www.heinkel -group.com
Optim imiza ization tion Task 29 …by www.heinkel -group.com
Result ult 30 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Understand Results Next Step: Creation CAD Model 31 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Creation of 3D Model Attachments: 1 Force: 100 N Weight: 77 g Next Step: Analyse new Design 32 …by www.heinkel -group.com
Examp mple e Wardrobe Hook Analyse of new Design Max Stress: 82.9 Mpa Max Deformation: 0.10 mm Next Step: Compare Models 33 …by www.heinkel -group.com
Examp mple Rendering Weight: -65 % Connecting Devices: -50 % Max Stresses: + 50 Mpa (Not critical) Deformation: -68 % 34 …by www.heinkel -group.com
Examp mple e Render derin ing Tutorial in Fusion 360 35 …by www.heinkel -group.com
Thank you for your Attention Tayfun Süle Teamleader ALM ts@bionic-studio.com BERATUNG | ENTWICKLUNG | DRUCK www.bionic-studio.com
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