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The present-day methods of numerical simulation offer a great variety of options for optimizing metal forming processes. Although it is possible to simulate complex forming processes, the results are typically available only as 2D projections on screens. Some forming processes have reached a level of complexity beyond the level of spatial sense, which makes it necessary to use physical 3D representations to develop a deeper understanding of the material flow, microstructural processes, process and design limits, or to design the required tooling. Physical 3D models can be produced in a short amount of time using 3D printing, and indexed with a wide range of colors. In this paper, the additive manufacturing of 3D color models based on simulation results are explored by means of examples from metal forming. Different 3D-printing processes are compared on the basis of quality as well as technical and economic criteria. Other examples from the fields joining by upset-bulging of tubes and microstructure simulation are also analyzed. This paper discusses the possibilities offered by the rapid progress and wide availability of 3D printers for the design and optimization of complex metal forming processes.
Architecture models are an essential component of the development process and enable a physical representation of virtual designs. In addition to the conventional methods of model production using the machining of models made of wood, metal, plastic or glass, a number of additive manufacturing processes are now available. These new processes enable the additive manufacturing of architectural models directly from CAAD or BIM data. However, the boundary conditions applicable to the ability to manufacture models with additive manufacturing processes must also be considered. Such conditions include the minimum wall thickness, which depends on the applied additive manufacturing process and the materials used. Moreover, the need for the removal of support structures after the additive manufacturing process must also be considered. In general, a change in the scale of these models is only possible at very high effort. In order to allow these restrictions to be adequately incorporated into the CAAD model, this contribution develops a parametrized CAAD model that allows such boundary conditions to be modified and adapted while complying with the scale. Usability of this new method is illustrated and explained in detail in a case study. In addition, this article addresses the additive manufacturing processes including subsequent post-processing.
Implementation of lightweight design in the product development process of unmanned aerial vehicles
(2017)
The development and manufacturing of unmanned aerial vehicles (UAVs) require a multitude of design rules. Thereby, additive manufacturing (AM) processes provide a number of significant advantages over conventional production methods, particularly for implementing requirements with regard to lightweight construction and sustainability. A new, promising approach is presented, with which, through the combination of very light structural elements with a ribbed construction, an attached covering by means of foil is used. This contribution develops and presents a development process that is based on various development cycles. Such cycles differ in their effort and scope within the overall development, and may only comprise one part of the development process, or the entire development process. The applicability of this development process is demonstrated within the framework of a comprehensive case study. The aim is to develop an additively manufactured product that is as light as possible in the form of a UAV, along with a sustainable manufacturing process for such product. Finally, the results of this case study are analyzed with regard to the improvement of lightweight construction.