Development, numerical simulation and experimental characterization of selective laser melting (SLM) microstructures with deliberately introduced dissipation

故意引入耗散的选择性激光熔化 (SLM) 微结构的开发、数值模拟和实验表征

• 批准号: 414180263
• 负责人: Professor Dr.-Ing. Wolfgang A. Wall
• 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: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/414180263?language=en
• 关键词: Development; numerical; simulation; experimental; characterization

Due to novel materials and innovative manufacturing technologies, the concept of lightweight design has become more and more prevalent within the last years. Unfortunately, the resulting technical components are often more sensitive to undesired vibrations. The aim of this proposal is to address these unwanted effects directly at their source by employing novel manufacturing technologies for the development of multi-functional microstructures that combine lightweight design with effective and controllable dissipation characteristics in an integral and multi-functional way. Concretely, we exploit the advantages of selective laser melting (SLM), a recent and very promising representative of powder-fusion-based additive manufacturing (AM) processes, in order to generate the intended microstructures. Due to the layer-wise production, the SLM process is capable of producing highly complex geometries that cannot be obtained by conventional manufacturing processes. This paradigm shift in mechanical design has already enabled the manufacturing of novel microstructures typically optimized in terms of weight and stiffness. In order to combine these lightweight designs with the desired damping characteristics, four fundamental microstructural concepts based on different physical dissipation phenomena such as micro-tribology, solid material damping and viscous damping in fluids are proposed: a microstructure consisting of loose metal powder (that is already provided by the SLM process), a porous microstructure filled with highly viscous oil, a lightweight metal lattice structure filled with solidified polymer resin, and finally an intelligent microstructure consisting of internal micro-friction elements that allow for damping of individual deformation modes. In order to investigate and implement the proposed concepts, the competences of the two participating institutions in terms of experimental and manufacturing expertise on the one hand and modeling and simulation related know-how on the other hand are combined in an optimal way. Accurate mechanical microscale models will be developed in order to investigate the underlying physical dissipation phenomena. Subsequently, these microscale models will be transferred into homogenized macroscale models, thus generating predictive simulation tools that allow for an efficient evaluation and optimization of the proposed damping concepts for practically relevant design parts. Detailed experimental investigations on custom-built samples will serve for an in-depth microstructure characterization, model parameter determination and eventually for verification of the derived models and validation of the proposed dissipation concepts. Based on the most promising concepts, a prototype in form of a cutting tool will be manufactured in order to assess the achievable damping characteristics also in a practically relevant environment.

由于新型材料和创新的制造技术，轻量化设计的概念在过去几年中变得越来越普遍。不幸的是，所得到的技术部件通常对不期望的振动更敏感。该提案的目的是通过采用新的制造技术来开发多功能微结构，从而直接从源头上解决这些不必要的影响，所述多功能微结构以整体和多功能的方式将联合收割机轻量化设计与有效和可控的耗散特性相结合。具体地说，我们利用选择性激光熔化（SLM）的优势，一个最近的和非常有前途的代表基于粉末熔化的增材制造（AM）工艺，以产生预期的微观结构。由于分层生产，SLM工艺能够生产通过常规制造工艺无法获得的高度复杂的几何形状。机械设计的这种范式转变已经使得能够制造通常在重量和刚度方面优化的新型微结构。为了将联合收割机这些轻质设计与所需的阻尼特性相结合，提出了基于不同物理耗散现象（例如微摩擦学、固体材料阻尼和流体中的粘性阻尼）的四种基本微结构概念：由松散的金属粉末组成的微观结构（这已经由SLM工艺提供），填充有高粘度油的多孔微观结构，轻质金属网格结构填充固化聚合物树脂，最后是智能微结构，由内部微摩擦元件组成，允许阻尼个别变形模式。为了研究和实施所提出的概念，两个参与机构在实验和制造专业知识方面的能力，以及建模和仿真相关的专业知识，以最佳的方式相结合。为了研究潜在的物理耗散现象，将建立精确的微尺度力学模型。随后，这些微尺度模型将被转换成均匀化的宏观尺度模型，从而生成预测性仿真工具，该工具允许对实际相关设计部件的拟议阻尼概念进行有效评估和优化。对定制样品的详细实验研究将用于深入的微观结构表征、模型参数确定，并最终用于验证推导的模型和验证提出的耗散概念。基于最有前途的概念，将制造一个切割工具的形式的原型，以评估可实现的阻尼特性，也在实际相关的环境。