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Integral lightweight design of gears via laser beam melting

通过激光束熔化进行齿轮整体轻量化设计

基本信息

批准号：
314876601
负责人：
Professor Dr.-Ing. Gunther Reinhart
金额：
--
依托单位：
Lehrstuhl für Betriebswissenschaften und Montagetechnik
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2016
资助国家：
德国
起止时间：
2015-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/314876601?language=en
关键词：
Integral lightweight design gears via

项目摘要

In increasing resource efficiency of gear drives lightweight design is essential in order to reduce the masses that have to be accelerated as well as the torque of inertia and therefore minimize irreversible energy losses. At the same time, unbalances may be decreased leading to an increased gear life. This also holds a secondary lightweight potential in designing surrounding gear components according to a reduced load induced by the primary component. Lightweight concepts have to be a trade-off between material strength, efficiency as well as NVH (Noise, Vibration, and Harshness). Hence, a consideration on a system, component as well as material and manufacturing level is crucial.The framework of this project focusses on the possibilities of lightweight design by means of a combination of construction, material and manufacturing relying on additive manufacturing via LBM (Laser Beam Melting). LBM offers the integrated manufacturing of highly complex and integrated structures due to a layer wise buildup of the part. At the same time, high strength materials may be used. The flexibility of LBM is employed to implement lightweight structures into less stressed part segments. These structures comprise classical topologies like load-adapted struts or lattice structures, which have to be evaluated based on simulations and experiments with regard to their static and fatigue strength. As a sub research objective, lattice structures for the implementation of a conformal gas cooling are evaluated. This way porous part segments are created that can be used as an evaporation cooling zone for special thermal conditions. In summary, the overall research objective is a comprehensive design guideline specifically for LBM for integrated lightweight gear wheels.

为了提高齿轮传动的资源效率，轻量化设计是必不可少的，以减少必须加速的质量以及惯性扭矩，从而最大限度地减少不可逆转的能量损失。同时，不平衡可以减少，从而增加齿轮寿命。这也持有二次轻量化的潜力，在设计周围的齿轮组件，根据减少负荷引起的主要组件。轻量化概念必须在材料强度、效率以及NVH（噪音、振动和粗糙度）之间进行权衡。因此，对系统、组件以及材料和制造水平的考虑是至关重要的。该项目的框架侧重于通过LBM（激光束熔化）的增材制造，通过结构、材料和制造相结合，实现轻量化设计的可能性。由于零件的分层构建，LBM提供了高度复杂和集成结构的集成制造。同时，可采用高强度材料。利用LBM的柔韧性将轻量化结构实现为小应力构件段。这些结构包括经典的拓扑结构，如负载适应支柱或晶格结构，必须基于模拟和实验来评估它们的静态和疲劳强度。作为一个子研究目标，晶格结构的实施保形气体冷却进行了评估。通过这种方式，可以创建多孔部件段，用作特殊热条件下的蒸发冷却区。综上所述，总体研究目标是为集成轻量化齿轮的LBM提供一个全面的设计指南。