Development of a Variable Gridshell for Application in Mobile Architecture

2019 ◽  
Vol 809 ◽  
pp. 541-546
Author(s):  
Enrico Rudolph ◽  
Christian Müller ◽  
Andreas Ehrlich ◽  
Sandra Gelbrich ◽  
Lothar Kroll
Keyword(s):  
Lightweight Design ◽  
High Potential ◽  
Support Structures ◽  
Lightweight Construction ◽  
Research Project

Within the research project a variable gridshell in lightweight design was developed that permit the building of free-formed mobile architectures. The construction consists of a large number of straight length-adjustable bars pin-jointed via so-called knots and enables extremely efficient and stable support structures with high potential for lightweight construction.

Bending of lightweight circular tubes

2017 ◽  
Vol 232 (7) ◽  
pp. 1165-1178 ◽  
Author(s):  
G Mastinu ◽  
G Previati ◽  
M Gobbi
Keyword(s):  
Lightweight Design ◽  
Analytical Form ◽  
Upper And Lower Bounds ◽  
Concept Design ◽  
Optimal Solutions ◽  
Lightweight Construction ◽  
Linear Elastic ◽  
Design Variables ◽  
Maximum Stiffness ◽  
Linear Elastic Theory

The concept design (sizing) of thin-walled tubes subject to bending is dealt by resorting to rigorous design principles pertaining to engineering science. Multi-objective optimization is the proper theory that has been exploited. Minimum mass and maximum stiffness (minimum compliance) are the optimization objectives. Safety (admissible stress), stability (buckling), available room (external radius of the tube), and thickness of the tube (arising from technological issues) are introduced as constraints. Linear elastic theory is used. Optimal solutions are given in analytical form for a prompt use by designers. Such optimal solutions refer both to the objectives (mass and compliance) and to the design variables (radius and thickness of the tube). The best attainable lightweight design is discussed as a function of the constraints. In particular, given the upper and lower bounds for radius and thickness respectively, three candidate optimal solutions are addressed in the paper for concept design purposes. The comparative lightweight design of tubes made from different materials is presented. Contrary with respect to the reputation of aluminum for effective lightweight construction, steel can be the best choice, when the available room has to be saturated.

Support Structures in Lightweight Design for the Construction of Resource Efficient Bridges

2015 ◽  
Vol 825-826 ◽  
pp. 699-706 ◽  
Author(s):  
Enrico Rudolph ◽  
Andreas Ehrlich ◽  
Sandra Gelbrich ◽  
Meike Röhrkohl ◽  
Lothar Kroll
Keyword(s):  
Mechanical Properties ◽  
Lightweight Design ◽  
Functional Integration ◽  
Support Structures ◽  
Force Transmission ◽  
Support Structure ◽  
Processing Technologies ◽  
Glass Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic

Modern civil engineering is characterized by resource and energy efficiency, and functional integration. The focus of modern architecture is therefore increasingly on free-formed buildings with organic shapes and biomorphic structures. The basis of new buildings still consists of conventional materials like steel, glass and reinforced concrete. However, the applicability of these materials is limited, regarding lightweight design, freedom of design, efficiency and functional integration. Innovative projects either cannot be implemented, or would be put to enormous costs and expenditure of resources.The theoretical and experimental basis for this functionally integrated support structure was established within the scope of the research project “New lightweight structural components and processing technologies for the application in support structures”, supported by the Sächsische Aufbaubank SAB.The main objective was to develop material and design for a lightweight modular support structure and to implement it by means of innovative production methods. New approaches included the application of glass-fiber-reinforced plastic (GFRP) due to its favorable mechanical properties, low susceptibility to corrosion and load-adjusted dimensioning.In connection with the realization of the production, different technological concepts were analyzed with reference to their suitability, integration of required force transmission and further functions during and after production. The lightweight elements were analyzed on a laboratory scale with regard to their production and their mechanical properties. A holistic production and tool concept resulted from these tests, that pictures the complete process chain from textile to component. The results were implemented in practice in form of an interactive honeycomb-bridge which was built in Chemnitz.

Folgeverbundhybridschmieden eines Querlenkers*/Hybrid forging process within progressive dies of a suspension arm – Lightweight structural construction and heat subjection of hybrid forged parts

2019 ◽  
Vol 109 (10) ◽  
pp. 765-769
Author(s):  
E. Seif ◽  
J. Langner ◽  
M. Stonis ◽  
B. Behrens
Keyword(s):  
High Potential ◽  
Lightweight Construction ◽  
Forging Process ◽  
Progressive Dies ◽  
Hardening Process ◽  
Forged Parts

Folgeverbundhybridgeschmiedete Bauteile haben großes Potenzial im Leichtbau. Am Beispiel eines Querlenkers wird der Vorteil des Hybridschmiedens in Struktur- und Stoffleichtbau betrachtet. Zusätzlich zeigt die Betrachtung des Wärmeeintrags, dass beim nachträglichen Vergüten das Potenzial des Stoffleichtbaus nicht gefährdet wird.   Components manufactured by hybrid forging in progressive dies have a high potential for lightweight construction. The example of a suspension arm shows the advantage of hybrid forged parts creating new possibilities for structural and material lightweight construction. Additionally, it is demonstrated that the heat subjected to hybrid forged parts during the subsequent hardening process does not threaten the potential of material lightweight construction.

New Multi-Material Design Concepts and High Integration Light Metal Applications for Lightweight Body Structures

2010 ◽  
Vol 638-642 ◽  
pp. 437-442 ◽  
Author(s):  
Gundolf Kopp ◽  
Elmar Beeh
Keyword(s):  
Lightweight Design ◽  
Steel Structure ◽  
Material Design ◽  
Light Metal ◽  
Attractive Potential ◽  
Reference Structure ◽  
Lightweight Construction ◽  
Design Concepts ◽  
Research Activities ◽  
Crash Performance

A major motivation for the development of new vehicle structures is, apart from the reduction of fuel consumption, is to decrease emissions which affect the climate. Therefore we also have to look at the reduction of vehicle weight and consequently at various strategies for lightweight construction. In the future steel structure concepts still show lightweight potential. But even more attractive potential for lightweight body in white structures could be realised by new multi-material design concepts and highly integrated light metal applications. Today’s research activities are focussed on the area of multi-material design, with the objective of placing the material with the best properties for the given requirements in the right position. Based on various methods of lightweight construction, techniques and tools, it is possible to find an optimum between lightweight design and costs. These activities will be illustrated by several research examples. One example will be the lightweight concept of the front module developed by the Institute of Vehicle Concepts (DLR) in the European research project -‘Super Light Car’ (SLC). By using aluminium in the front structure and the high pressure die casting strut tower the concept has a weight benefit of 32% compared to a steel reference structure. The methodology for reaching targets and requirements like weight reduction, crash performance and cost targets will be explained. Another example is a concept which is developed in the DLR project ‘Novel Vehicle Structures’. This concept shows the combination of different materials and a new construction method to increase front impact crash performance.

scholarly journals Introduction to tailored forming

2021 ◽  
Author(s):  
B.-A. Behrens ◽  
J. Uhe
Keyword(s):  
Collaborative Research ◽  
Lightweight Design ◽  
Production Quality ◽  
Research Centre ◽  
Lightweight Construction ◽  
Forming Process ◽  
Process Chains ◽  
Finishing Processes ◽  
Tailored Forming ◽  
Joining Process

AbstractIn recent years, the requirements for technical components have been increasing steadily. This development is intensified by the desire for products with lower weight, smaller size and extended functionality, but at the same time higher resistance against specific loads. Mono-material components manufactured according to established processes reach their limits regarding conflicting requirements. It is, for example, hardly possible to combine excellent mechanical properties with lightweight construction using mono-materials. Thus, a significant increase in production quality, lightweight design, functionality and efficiency can only be reached by combining different materials in one component. The superior aim of the Collaborative Research Centre (CRC) 1153 is to develop novel process chains for the production of hybrid solid components. In contrast to existing process chains in bulk metal forming, in which the joining process takes place during forming or at the end of the process chain, the CRC 1153 uses tailored semi-finished workpieces which are joined before the forming process. This results in a geometric and thermomechanical influence on the joining zone during the forming process which cannot be created by conventional joining techniques. The present work gives an overview of the CRC and the Tailored Forming approach including the applied joining, forming and finishing processes as well as a short summary of the accompanying design and evaluation methods.

Application of a Lightweight Engineering Tool: Lazy Parts Analysis and Redesign of a Remote Controlled Car

2011 ◽  
Author(s):  
David Griese ◽  
Essam Namouz ◽  
Prabhu Shankar ◽  
Joshua D. Summers ◽  
Gregory Mocko
Keyword(s):  
Topology Optimization ◽  
Remote Control ◽  
Material Removal ◽  
Lightweight Design ◽  
High Potential ◽  
Mass Reduction ◽  
Indicator Method ◽  
Entire Process ◽  
Original Mass ◽  
Lightweight Engineering

The objective of this study was to implement the Lazy Parts Indicator Method (LPIM) in the analysis of a remote control (RC) car to identify potential parts for mass reduction. In addition, an example of how the method can be used in conjunction with a part redesign process has been shown through topology optimization of an identified part. The LPIM, which was originally developed for the analysis of automobiles, serves as a set of guidelines for novice designers to identify components that have potential for mass reduction. By successfully using the method on a RC car, the method can be shown to be applicable on smaller scale. The analysis of the RC car consisted of using indicators to identify lazy parts, weighing of those parts, and estimation of mass reduction percentages. From this, it was estimated that approximately 5% of the vehicle’s weight could be reduced. Once the lazy analysis was completed on the car, a component with a high potential for mass reduction was selected for redesign. Topology optimization using ANSYS Mechanical was done to suggest a new design, which contained regions of material removal. After creating a redesigned part, a new mass was measured and used to validate the original mass reduction estimates from the LPIM. The new part design was also validated through physical experimentation in which the part was fabricated and tested. This paper outlines an entire process for lightweight design from start to finish, beginning with an identification of parts with mass reduction using the Lazy Parts Indicator Method.

scholarly journals A Lightweight Design of Tree-shaped Support Structures for SLM Additive Manufacturing

2019 ◽  
Vol 17 (4) ◽  
pp. 716-726
Author(s):  
Lin Zhu ◽  
Ruiliang Feng ◽  
Juntong Xi ◽  
Peng Li ◽  
Xiangzhi Wei
Keyword(s):  
Additive Manufacturing ◽  
Lightweight Design ◽  
Support Structures

Deflection Sheaves for Elevator Application in Lightweight Design

2019 ◽  
Vol 809 ◽  
pp. 347-352
Author(s):  
Hendrik Gerlach ◽  
Hartwig Müller ◽  
Marcus Klingelhöfer ◽  
Roland Ziesch ◽  
Mikolaj Katkowski ◽  
...  
Keyword(s):  
Cast Iron ◽  
Lightweight Design ◽  
Material Design ◽  
Local Area ◽  
Design Tool ◽  
High Potential ◽  
Fibre Reinforcement ◽  
Basic Part ◽  
Cycle Times ◽  
Reinforced Thermoplastics

Current elevators are mostly designed as rope-dependent elevators. Main components in the roping system are the deflection sheaves which are conventional manufactured of grey cast iron. Due to the high weight of cast iron sheaves there is a high potential for reducing mass, especially when regarding aspects of effort, safety and ergonomics while assembly and maintenance in the elevator shaft. Within the framework of a R&D co-operation the Chemnitz University of Technology and the AMB Oberlungwitz GmbH developed a fibre-reinforced plastic sheave that comply with the requirements of lightweight design. The technological basic approach to realize that development is compression molding of glass-mat-reinforced thermoplastics (GMT). The project includes the whole development-chain, consisting of part design, tool design, process chain arrangement, parameter studies as well as validation of specimen. In the course of the project appeared a high potential for improvement of the part properties by alternative design solutions. In this context current activities are focused on multi material design methods such as combining GMT with other thermoplastic prepregs. In this manner it is possible to equip every local area with the specific properties that are required. For example the ribs of the sheave, that receive highest values of stress, can be made of materials with continuous-fibre-reinforcement while the basic part body consists of GMT, which is long-fibre-reinforced. This method also enables to avoid process influenced effects like the segregation of the fibre-matrix distribution in GMT. Additionally the input of different materials offers chances to inlay non-preheated prepreg blanks into the compression mould, so that the amount of the preheated material volume can be reduced. In this way cycle times and also lost of temperature due to transfer times of the heated blanks to the mould can be reduced.

Additiver Hybrid-Leichtbau – Highlight 3D print*/Additive Hybrid Lightweight Construction - Highlight 3D print

2016 ◽  
Vol 106 (03) ◽  
pp. 169-174
Author(s):  
R. Geiger ◽  
S. Rommel ◽  
J. Burkhardt ◽  
T. Prof. Bauernhansl
Keyword(s):  
Additive Manufacturing ◽  
Lightweight Design ◽  
High Strength ◽  
Fiber Reinforced ◽  
Lightweight Construction ◽  
Specific Product ◽  
3D Print ◽  
Reinforced Plastic ◽  
Fiber Reinforced Materials ◽  
New Construction

Additive Fertigungsverfahren bieten durch ihren schichtweisen Aufbau einzigartige Gestaltungsfreiheiten. Hieraus leitet sich ein enormes Potential für den strukturellen Leichtbau ab. Bionische Leichtbaustrukturen, integrierte Funktionalitäten sowie topologieoptimierte Bauteile lassen sich direkt produzieren. Neben dem strukturellen Leichtbau lassen sich durch die Verwendung hochfester Werkstoffe oder von Werkstoffen mit geringer Dichte ebenfalls Leichtbauprodukte generieren. Ein Beispiel für werkstofflichen Leichtbau sind Faserverbundstrukturen, welche geringe Materialdichte mit hoher Festigkeit kombinieren. Durch Bündelung der Vorteile additiver Fertigungsverfahren mit Halbzeugen aus Hochleistungswerkstoffen – beispielsweise kohlenstofffaserverstärkten Kunststoffen – werden noch leichtere Produkte möglich. Besonders die Funktionsintegration und die Designfreiheit additiver Verfahren schaffen hier völlig neue Gestaltungsmöglichkeiten und einen Individualisierungsgrad, der im Leichtbau bisher unbekannt ist. Anhand eines Produktbeispiels wird aufgezeigt, welche Potentiale additiver Hybrid-Leichtbau eröffnet. Ausgehend von einer topologieoptimierten Form erfolgt die Ableitung eines Bauteils. Dies wird im Lasersinterverfahren (SLS) gefertigt und in Kombination mit Kohlenstofffaserverbund (CFK)-Rohren sowie weiteren additiv gefertigten Bauteilen zum Produkt „Hocker“ zusammengefügt. Parallel wird das Verbundsystem digital abgebildet und simulativ überprüft.   Additive manufacturing technology offers unique design flexibility due to its layer-based construction approach. This provides new potential for lightweight construction. Bionic lightweight structures, integrated functionality, and topology-optimized structures can now be manufactured. Another method to generate lightweight design is the use of high-strength materials with low density. For example, fiber reinforced materials which combine high-tensile fibers with low material density. The combination of these two unique benefits leads towards ultra-light products. The degree of individualization through additive manufacturing represents a new tool in the field of lightweight design, providing new construction possibilities. This paper presents the potential of hybrid lightweight design with the help of a specific product. An ergonomic lightweight seat starts with a topology optimized 3D form. The construction combines additive manufactured parts with carbon fiber reinforced plastic (CFRP) pre-products. Additionally, the interaction between the constituent parts has been simulated.

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