Session: 06-04-01 Design for Additive Manufacturing I

Paper Number: 70887

Start Time: Friday, 11:45 AM

70887 - Components Residual Stress and Deformation Reduction: An Integrated Process Design for Additive Manufacturing Residual Stress and Deformation Reduction: An Integrated Process Optimization for Design for Additive Manufacturing 

Additive Manufacturing is a key technology in current industrial transformations thanks to the significant benefits that can bring to high-level sectors. Nevertheless, Additive Manufacturing (AM) based design approaches are still under study and further improvements are fundamental in order to exploit potentials of the technology. With regards to sundry approaches of Design for Additive Manufacturing (DfAM), concurrent improvements on product and process rely on definition of techniques and guidelines as well as related methods, systems and tools development. Referring to metal AM, main DfAM elements can be encased in product optimization and process optimization. The first aims to an effective achievement of enhanced products requirements related to high geometrical complexity allowed by the technology. The last aims to improve process reliability concerning not only feasibility and economic considerations but also to achieve the aforementioned requirements through reduction of material and shape defects, residual stress and induced distortions on final components. This work focuses on integrated DfAM approaches for product-process design, to meet both functional and technological targets. Thus, main elements of process optimization are summarized and the design method to perform process optimization is presented. The approach consists of industrialization task improvement based on modelling optimization and printing optimization sub-phases supported by numerical process simulation. Integration of CAD platforms allows these linked steps to be performed downstream of the product design, which can be achieved through functional or multifunctional optimization techniques as well (e.g. topology optimization, latticing, graded structures/materials). The presented approach is supported by previous preliminary studies on process simulations. Firstly, a study on simulation setup considering specific steps, results type, workflow feasibility and suitability for the method was conducted. Secondly, a study focused on numerical results accuracy compared to experimental results was performed to validate predictive approaches. Moreover, a study to streamline process simulation in order to balance results accuracy and computational cost was performed to make the numerical approach usable for actual part scale level computation. The process optimization design method is finally applied in the DfAM context, to perform the industrialization phase of a high performance automotive component. The case study is from a braking system of a formula SAE car, or rather a topology optimized brake caliper to be produced by Selective Laser Melting process. The study stresses the method on a first complex case at part scale level, demonstrating its applicability to industrial context to improve the industrialization phase in the redesign of components to be produced by Powder Bed Fusion technologies.

Presenting Author: Enrico Dalpadulo "Enzo Ferrari" Department of Engineering, University of Modena and Reggio Emilia

Authors:

Enrico Dalpadulo University of Modena and Reggio Emilia
Fabio Pini University of Modena and Reggio Emilia
Francesco Leali University of Modena and Reggio Emilia