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AddMan

AddMan

Title: Innovative Re-Design and Validation of Complex Airframe Structural Components Formed by Additive Manufacturing for Weight and Cost Reduction
Project No: 738002
Start date: 1st of Januray 2017
Duration: 36 months
Contact point: Svjetlana Stekovic, e-mail: svjetlana.stekovic@liu.se, +46 701 91 66 76
Anders Klarbring, e-mail: anders.klarbring@liu.se, +46 13 28 11 17

Project overview

Additive manufacturing (AM) is a technology by which physical objects can be built directly from 3D Computer Aided Design (CAD) data, and is widely acknowledged as an enabler for revolutionizing the manufacturing landscape. It replaces traditional production methods like casting and machining, and enables essentially arbitrary geometric shapes to be produced. Although significant progress has been made on AM hardware development, there is a lack of efforts regarding material characterization, design tools and methods to efficiently bring AM to practical use in the aeronautical area. In particular, Topology optimization (TO) – a finite element based design method – is an unusually evident and potentially fruitful technique for designing AM structures. However, the mechanical properties of AM components differ substantially from the properties of the same components produced by conventional methods, and AM components can have complex shapes, such as grid-like structures, that cannot be achieved by using conventional production methods. Therefore, the AddMan project deals with:

  • Material characterization by establishing fatigue properties and geometry dependent material behavior as well as AM specific build requirements,
  • Development of novel TO methods, as well as CAE methods for metal AM which make use of the material properties generated in AddMan,
  • Development of design for AM guidelines that are implemented in an automated knowledge based engineering framework including connection between TO and flexible parametric CAD models, to enable holistic product optimization, and
  • Development of a cost effective post-processing strategy for AM components in order to increase fatigue performance.

Project objectives

The objectives of AddMan are:
  • Characterization of AM manufactured parts to determine the effect of geometry, microstructure, surface roughness and residual stresses on material behaviour to enable optimization of fatigue performance by cost effective surface post processing (WP2),
  • Extension of existing Topology Optimization (TO) techniques for AM specific material characteristics and complex geometries for optimal performance and structural strength (WP3),
  • Development of CAE methods for metal AM including connection to TO and flexible parametric CAD models to enable holistic product optimization (WP4), and
  • Demonstration of the applicability of the developed methods and tools by designing and manufacturing airframe titanium components by using AM technology, where the validation will be carried out through component like specimen testing (WP5).

Project partners

The consortium consists of a unique team that have extensive experience with AM, mechanical testing, material behaviour, TO, CAD, modelling and machine design. Both LiU and MTC have a strong background in structural optimization (particularly TO and shape optimization), robust deterministic optimization, parametric modelling, manufacturing, mechanical testing (fatigue, tensile, hardness, etc.) and understanding of mechanical behaviour. The partners are:

News

The kick-off meeting took place at Linköping University and Saab in Linköping, Sweden, between 2-3 of February 2017. The purpose of the meeting was to:
  • Officially start AddMan,
  • Present partners and participants,
  • Develop a common understanding of the project, its objectives, tasks and expected results,
  • Present and discuss the WP activities,
  • Clarify project management and administrative procedures, and
  • Agree on next steps.
The meeting was chaired by both the Project Coordinator (Svjetlana Stekovic) and the Topic Manager (Magnus Kahlin).

Dissemination

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Page responsible: Bo Torstenfelt
Last updated: 2017-05-09