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The ability to change aerodynamic parameters of airfoils during flying can potentially save energy as well as reducing the noise made by the unmanned aerial vehicles (UAV) because of sharp edges of the airfoil and its rudders. In this paper, an approach for the design of an adaptive wing using a multi-material 3D printer is shown. In multi-material 3D printing, up to six different materials can be combined in one component. Thus, the user can determine the mixture and the spatial arrangement of this “digital material” in advance in the pre-processing software. First, the theoretical benefits of adaptive wings are shown, and already existing adaptive wings and concepts are explicated within a literature review. Then the additive manufacturing process using photopolymer jetting and its capabilities to print multiple materials in one part are demonstrated. Within the scope of a case study, an adaptive wing is developed and the necessary steps for the product development and their implementation in CAD are presented. This contribution covers the requirements for different components and sections of an adaptive wing designed for additive manufacturing using multiple materials as well as the single steps of development with its different approaches until the final design of the adaptive wing. The developed wing section is simulated, and qualitative tests in a wind tunnel are carried out with the wing segment. Finally, the additively manufactured wing segment is evaluated under technical and economic aspects.
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 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.