Generative Design and Topology Optimization of Analysis and Repair Work of Industrial Robot Arm Manufactured Using Additive Manufacturing Technology

Low emission combustion is one of the most important requirements for Industrial gas turbines. Siemens Industrial gas turbines SGT-800 and SGT-700 use DLE (Dry Low Emission) technology and are equipped with 3rd generation of DLE burners. These burners demonstrate high performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially the tip repair has been done by conventional methods — i.e. cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of AM (Additive Manufacturing) technology it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including: a) machining off of the damaged and oxidized tip, b) positioning the sintered model on the burner face, c) sintering a new tip in place, d) quality assurance and inspection methods, e) powder handling, f) material qualification including bonding zone, g) development of methods for mechanical integrity calculation, h) qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification and repair work shop set-up.

Download Full-text

REDESIGN AND TOPOLOGY OPTIMIZATION OF AN INDUSTRIAL ROBOT LINK FOR ADDITIVE MANUFACTURING

Facta Universitatis Series Mechanical Engineering ◽

10.22190/fume181219003t ◽

2019 ◽

Vol 17 (3) ◽

pp. 415 ◽

Cited By ~ 1

Author(s):

Evangelos Tsirogiannis ◽

George-Christopher Vosniakos

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Strain Energy ◽

Industrial Robot ◽

Selective Laser Sintering ◽

Maximum Strain ◽

Trial And Error ◽

Optimization Software ◽

And Topology ◽

Strength And Stiffness

Design optimization for Additive Manufacturing is demonstrated by the example of an industrial robot link. The part is first redesigned so that its shape details are compatible with the requirements of the Selective Laser Sintering technique. Subsequently, the SIMP method of topology optimization is utilized on commercially available software in order to obtain the optimum design of the part with restrictions applicable to Additive Manufacturing, namely member thickness, symmetry and avoidance of cavities and undercuts. Mass and strain energy are the design responses. The volume was constrained by a fraction of the initial mass. The desired minimization of maximum strain energy is expressed as an objective function. A 7% reduction in the mass of the part was achieved while its strength and stiffness remained unchanged. The process is supported by topology optimization software but it also involves some trial-and-error depending on the designer’s experience.

Download Full-text

IMPLEMENTATION OF OPTIMUM ADDITIVE TECHNOLOGIES DESIGN FOR UNMANNED AERIAL VEHICLE TAKE-OFF WEIGHT INCREASE

EUREKA Physics and Engineering ◽

10.21303/2461-4262.2020.001514 ◽

2020 ◽

pp. 50-60

Author(s):

Sven Maricic ◽

Iva Mrsa Haber ◽

Ivan Veljovic ◽

Ivana Palunko

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Weight Ratio ◽

Goal Function ◽

Manufacturing Technology ◽

Generative Design ◽

Additive Manufacturing Technology ◽

3D Printed ◽

Lift Off ◽

The Right

The aim of this paper is to investigate the possibility of drone optimization by selecting and testing the best material suitable for additive manufacturing technology and generative design approach, i. e. shape optimization. The use of additive manufacturing technology enables the creation of models of more complex shapes that are difficult or impossible to produce with conventional processing methods. The complex and unconventional design of the drone body can open up many possibilities for weight reduction while maintaining the strength of the drone body. By using 3D printing in addition to FEM (Finite Element Method) analysis, and generative design it can identify areas of the drone body that are overdrawn, allowing it to either lift off material or simply change the design at these areas. Choosing the right material for this application is crucial in order to optimise the mechanical properties of the material with weight, material cost, printability and availability of the material and the 3D printing method, while at the same time reducing environmental pollution. The goal is to reduce the drone mass by 15–20 % using generative design tools. Mass is an important segment when prototyping a drone. If the drone is too heavy, more lift power is needed to keep the drone in the air, so the propellers have to turn faster and use more energy. Consequently, the reduction of drone mass should increase the take-off weight. In this article 5 commercial drones of similar characteristics are compared with the final proposal of our 3D printed drone (Prototype 1). The rotor distance between the drones, the weight of the electric motor and the take-off weight are compared. The goal was to produce a prototype with a big rotor distance-to-weight ratio, and take-off weight bigger than observed drones have. The defined goal function was optimized in order to evaluate characteristics of 12 different 3D printed materials. Following properties: ultimate strength, stiffness, durability, printability of the material, and required bed and extruder temperature for printing were taken in consideration to select optimal material. Polycarbonate proved to be the best choice for 3D printing UAVs

Download Full-text

Research and Experimental Verification on Topology-Optimization Design Method of Space Mirror Based on Additive-Manufacturing Technology

Machines ◽

10.3390/machines9120354 ◽

2021 ◽

Vol 9 (12) ◽

pp. 354

Author(s):

Yanchao Fan ◽

Deyi Dong ◽

Chao Li ◽

Yuxin Sun ◽

Zhiyu Zhang ◽

...

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Design Method ◽

Diamond Turning ◽

Manufacturing Technology ◽

Surface Shape ◽

Mirror Surface ◽

Optical Surface ◽

Shape Accuracy ◽

Additive Manufacturing Technology

As one of the most-critical components in space optical cameras, the performance of space mirrors directly affects the imaging quality of space optical cameras, and the lightweight form of mirror blanks is a key factor affecting the structural quality and the surface-shape accuracy of mirrors. For the design requirements of lightweight and high surface-shape accuracy with space mirrors, this study proposes a design and manufacturing method that integrates topology-optimization with additive-manufacturing technology. This article firstly introduced the basic process and key technologies of space-mirror design and analyzed the superiority of combining a topology-optimized configuration design and additive-manufacturing technology; secondly, the topology-optimized design method of a back-open-structure mirror was used to complete the scheme design of a Φ260 mm aperture mirror; finally, the laser selective-melting manufacturing technology was used to complete the Φ260 mm aperture mirror blank. The mirror and its support structure were assembled and tested in a modal mode; the resonant frequencies of the mirror assembly were all over 600 Hz; and the deviation from the analytical results was within 2%. The optical surface of the mirror was turned by the single-point diamond-turning (SPDT) technique. The accuracy of the optical surface was checked by a Zygo interferometer. The RMS accuracy of the mirror surface was 0.041λ (λ is the wavelength; λ = 632 nm). In the test of the influence of gravity on the surface-shape accuracy, the mirror was turned over, which was equivalent to twice the gravity, and the RMS of the mirror surface-shape accuracy was 0.043λ, which met the requirement. The verification results show that the mirror designed and fabricated by the additive-manufacturing-based mirror-topology-optimization method can be prepared by the existing process, and the machinability and mechanical properties can meet the requirements, which provides an effective development method for improving the structural design and optimizing the manufacturing of space reflectors.

Download Full-text

Developing Additive Manufacturing Technology for Burner Repair

Journal of Engineering for Gas Turbines and Power ◽

10.1115/1.4034235 ◽

2016 ◽

Vol 139 (3) ◽

Cited By ~ 9

Author(s):

Olov Andersson ◽

Andreas Graichen ◽

Håkan Brodin ◽

Vladimir Navrotsky

Keyword(s):

Additive Manufacturing ◽

Gas Turbines ◽

Research Work ◽

Manufacturing Technology ◽

Heat Radiation ◽

Original Design ◽

Repair Work ◽

Additive Manufacturing Technology ◽

Low Emission ◽

Industrial Gas Turbines

Low emission combustion is one of the most important requirements for industrial gas turbines. Siemens industrial gas turbines SGT-800 and SGT-700 use dry low emission (DLE) technology and are equipped with third generation of DLE burners. These burners demonstrate high-performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially, the tip repair has been done by conventional methods— i.e., cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner, the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of additive manufacturing (AM) technology, it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including the following: machining off of the damaged and oxidized tip, positioning the sintered model on the burner face, sintering a new tip in place, quality assurance and inspection methods, powder handling, material qualification including bonding zone, development of methods for mechanical integrity calculation, and qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification, and repair work shop set up.

Download Full-text

Examination of possibilities of the strength modification in the case of FDM/FFF manufacturing technology

Design of Machines and Structures ◽

10.32972/dms.2020.010 ◽

2020 ◽

Vol 10 (2) ◽

pp. 27-34

Author(s):

Péter Ficzere ◽

Norbert László Lukács

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Manufacturing Technology ◽

Point Of View ◽

Main Body ◽

Generative Design ◽

Mechanical Stiffness ◽

Know How ◽

3D Printed ◽

Manufacturing Technologies

In many situations the result of the topology optimization or generative design can be manufactured only by additive manufacturing technologies. It is also important to know how the optimised shape behaves from the mechanical stiffness, the manufacturing technology and beneficial point of view. These two different goals can be combined and just the infill properties can be changed and optimised within the main body of 3D printed part.

Download Full-text