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Structural Optimization in Lightweight Design for Additive Manufacturing

  • The development of new processes and materials for additive manufacturing is currently progressing rapidly. In order to use the advantages of additive manufacturing, however, product development and design must also be adapted to these new processes. Therefore it is suitable to use structural optimization. To achieve the best results in lightweight design, it is important to have an approach thatThe development of new processes and materials for additive manufacturing is currently progressing rapidly. In order to use the advantages of additive manufacturing, however, product development and design must also be adapted to these new processes. Therefore it is suitable to use structural optimization. To achieve the best results in lightweight design, it is important to have an approach that reduces the volume in the unloaded regions and considers the restrictions and characteristics of the additive manufacturing process. In this contribution, a case study using a humanoid robot is presented. Thus, the pelvis module of a humanoid robot is optimized regarding its weight and stiffness. Furthermore, an integrated design is implemented in order to reduce the number of parts and the screw connections. The manufacturing uses a new aluminum-based material that has been specially developed for use in additive manufacturing and lightweight construction. For the additive manufacturing by means of the Selective Laser Melting (SLM) process, different restrictions and the assembly concepts of the humanoid robot have to be taken into account. These restrictions have to be considered in the setting of the individual parameters and target functions of the structural optimization. As a result, a framework is presented that shows the steps of the redesign and the optimization of the pelvis module. In order to achieve high accuracy with the product, the redesign of the pelvis module is demonstrated with regard to mechanical and thermal postprocessing. Finally, the redesigned part and the different assembly concepts are compared to analyze the economic and technical effects of the optimization.show moreshow less

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Metadaten
Author:Stefan JunkGND, Benjamin Klerch, Ulrich HochbergGND
Editor:Goran D. Putnik
Publisher:Elsevier
Date of Publication (online):2019/09/04
Language:English
Parent Title (English):Procedia CIRP
Volume:84
ISSN:2212-8271
First Page:277
Last Page:282
Document Type:Conference Proceeding
Institutes:Hochschule Offenburg / Bibliografie
Acces Right:Frei zugänglich
Release Date:2020/01/07
Licence (German):License LogoCreative Commons - CC BY-NC-ND - Namensnennung - Nicht kommerziell - Keine Bearbeitungen 4.0 International
Note:
29th CIRP Design Conference 2019, 08-10 May 2019, Póvoa de Varzim, Portgal
DOI:https://doi.org/10.1016/j.procir.2019.04.277