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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.
Das Team „Schluckspecht“ stellte sich im September 2010 einer besonderen Herausforderung. Neben der jährlichen Teilnahme am Shell Eco-Marathon ging das Team mit einem neu entwickelten Elektrofahrzeug an den Start der South Africa Solar Challenge. Für die Nutzung von Akkumulatoren als Energielieferant im Leichtfahrzeug „Schluckspecht E“ (im weiteren Verlauf als Batterien bezeichnet) wurde ein neues Strukturkonzept in Zusammenarbeit der Hochschule Offenburg mit dem Fraunhofer-Institut für Kurzzeitdynamik, Ernst-Mach-Institut, EMI entwickelt.
1000 Meilen unter Strom, Rekordfahrt des in Offenburg entwickelten eFahrzeugs "Schluckspecht"
(2012)
Nach der Entwicklung eines sparsamen Demonstrationsfahrzeugs mit Dieselmotor und Brennstoffzellenfahrzeuge wurde ein Batteriefahrzeug entwickelt, das in Südafrika unter der Aufsicht von FIA-Ingenieuren 626,6 km fuhr, ohne dass die Batterie aufgeladen werden musste. Ein Demonstrationsfahrzeug des Japan Electrical Vehicle Club hielt den damaligen Weltrekordmit 555,6 km.