Design, calculation and manufacturing of filigree structures with laser beam melting

激光熔化等附加制造工艺提供了从金属材料经济高效地制造复杂几何形状的可能性。虽然为生产固体部件建立的工艺链已经可靠地提供了良好的结果，但丝状格子结构可能会显示出显著的几何和质量偏差。到目前为止，这些差异阻碍了额外制造的格子在承重部件中的生产性使用。在最初的研究项目中，申请人开发了一种替代工艺链，使其能够将精细的晶格结构直接集成到CAD环境中的组件中，然后使用适当的曝光策略生产尺寸准确的组件。为此，开发了CAD插件和切片算法等软件组件，以及Ti6Al4V材料的曝光策略和激光参数等制造基础。然而，几何和质量上的优势仅限于周期晶格，需要相当大的手动工作才能进行鉴定。这些赤字将在拟议的项目中消除。其目的是调查通常与结构部件有关的质量标准对几何和技术规范的依赖程度，这比最初的项目更密切。在这门课程中，将制定一个实验计划，通过该计划，可以减少适应特定制造场景所需的个别实验的数量。通过单独考虑和改进各个压杆和节点之间的力学决定区域，可以进一步提高网架结构的力学性能。在软件方面，目标是集成非规则的网格结构，因为这允许组件根据个别应用程序和负载情况进行理想的适配。重点继续放在从模拟结果生成的自相似和共形不规则晶格上。要调查的制造问题的各个方面集中在已开发的曝光策略的演变上。一方面，这是一个进一步改善晶格质量的问题，特别是通过开发和测试合适的扫描策略和参数来提高表面质量和减少粉末与支柱的粘附性。另一方面，减少对新生产方案的工作流程进行鉴定所需的工作量只是一个概念问题。

Additve manufacturing processes such as laser beam melting offer the possibility of cost-efficiently manufacturing complex geometries from metallic materials. While the process chain established for the production of solid components already reliably delivers good results, filigree lattice structures can show significant geometric andqualitative deviations. These discrepancies have so far hindered the productive use of additively manufactured lattices in load-bearing components. In the initial research project, the applicants have developed an alternative process chain which makes it possible to integrate fine lattice structures directly into components in the CADenvironment and then produce them dimensionally accurate, using appropriate exposure strategies. For this purpose, software components such as a CAD plug-in and slicing algorithms as well as manufacturing fundamentals like exposure strategies and laserparameters for the material Ti6Al4V have been developed. However, the geometric and qualitative advantages are limited to periodic lattices and require a considerable manual effort for qualification. These deficits are to be eliminated in the proposed project. The aim is to investigate the dependency of the quality criteria, typically relevant for structural components, on the geometric and technological specifications more closely than it was possible in the initial project. In this course, an experimental plan is to be developed by which the number of necessary individual experiments for the adaption ofspecific manufacturing scenarios can be reduced. By a separate consideration and improvement of the mechanically decisive area at the transition between the individual struts and the nodes, the mechanical performance of the lattice structures shall be further increased. On the software side, an integration of non-regular lattice structures is aimed at, as this allows an ideal adaptation of the component to the individual application and load case. The focus continues to be on self-similar and also conformal irregular lattices, generated from simulation results. Aspects of manufacturing issues tobe investigated focus on the evolution of the developed exposure strategies. On the one hand, it is a matter of further improving the lattice quality, in particular an increase of the surface quality and a reduction of the powder adhesion to the struts by developing andtesting adapted scan strategies and parameters. On the other hand it is a matter of a concept to reduce the effort required to qualify the workflow for new production scenarios.