Autor: Albert Albers

By integrating specific material properties through the manufacturing process Selective Laser Melting (SLM) into a topology optimization, the product engineer can be supported by simulation in the design process. For this purpose, a topology optimization method is being developed which takes the process-specific material properties of the SLM into account during the optimization process. This method is part of a project funded by the German Research Foundation (DFG). In this article, the influence of these specific material properties on the design is presented.

Design and production of micro-mechanical assemblies is characterized by complex challenges. The small dimensions of the components are close to physical limits of micro manufacturing processes. Shape deviations cannot be avoided. They affect the interaction of single components and may even cause malfunction. At IPEK - Institute of Product Engineering Karlsruhe, a quality management strategy is developed that allows identifying the impact of shape deviations on the functional interaction of micro gears. Shape deviations can be detected and analyzed in order to find matching gears without the risk of malfunction.

Structural optimization based on the finite elements method is a tool for the Design identification and optimization of technical structures within the product development process. Advantages are a substantial process acceleration by reducing classical “optimization loops” and the possibility to find solutions which are empirically not attainable. In the past, a disadvantage of the method was that the algorithms suggested partially drafts which were not or only at unacceptable costs producible. From this the motivation arose to develop the manufacturing restrictions for structural optimization tools, presented in the following. By means of these restrictions the solution area of the optimization will be limited to a given manufacturing method, so that optimized, producible drafts are developed.