Abstract
In the Collaborative Research Centre (CRC) 1153, the process chain for the manufacture of hybrid high-performance components by Tailored Forming is being investigated. This involves the production of hybrid solid components. These have properties that are locally adapted to the respective load case, by combining different materials. The application potential of these multi-material components arises mainly where conventional mono-material components reach their technological development limits.
However, the Tailored Forming process chain is more complex than conventional forming processes, as the combination of materials results in a larger solution space when designing components, because the distribution of materials must also be taken into account. Tailored Forming is also a new manufacturing technology whose fundamentals are currently being researched. So, there is only a small number of manufactured samples whose properties have not yet been adequately analyzed. As a result, few design guidelines are known to date according to which Tailored Forming components can be designed.
In order to make statements about an optimized shape, the topology optimization method Interfacial Zone Evolutionary Optimization (IZEO) has been developed, which can be used to determine the material distribution for Tailored Forming components. Therefore, the manufacturing restrictions of Tailored Forming are numerically translated into geometric constraints that restrain the evolution throughout the optimization process. The solution achieved delivers a gross distribution of materials in the specified domain, while obeying the manufacturing constraints imposed. Further design development includes a fine construction of the model, where specific analysis can be executed about the joining zone of the different materials. With this process, the solution space can be efficiently explored and manufacturable designs can be produced, from which first guidelines for the construction of Tailored Forming components are derived.
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Acknowledgements
The results presented in this paper were obtained within the Collaborative Research Centre 1153 (Project number: 252662854) ‘‘Process chain to produce hybrid high performance components by Tailored Forming’’ in the subproject C2. The authors would like to thank the German Research Foundation (DFG) for the financial and organizational support of this project.
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Brockmöller, T., Siqueira, R., Mozgova, I., Lachmayer, R. (2021). Operationalization of Manufacturing Restrictions for Hybrid Tailored Forming Components. In: Dröder, K., Vietor, T. (eds) Technologies for economic and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-62924-6_29
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