Method for solving the design space restrictions by combining differential design and downstream joining connection

该项目的目的是开发一种基于差异设计和后续连接的大体积组件分离方法。螺栓连接适合作为增材制造中的代表性连接技术，因为它们是一种广泛使用且易于理解的连接方法。连接区的可访问性和设计代表了有待详细说明的方法的一个具有挑战性的用例。轻质合金AlSi 10 Mg的基于粉末床的激光束熔化用作增材制造工艺，申请人对此具有大量工艺知识。通过对L-PBF工艺和螺栓连接工艺步骤的设计方法分析，实现了所开发方法在其他连接技术中的可移植性。将省略单个演示器，而是使用多个特定于用户的案例研究来开发数据库。除了整体构造方法之外，为了满足对部件的甚至是矛盾的要求，将越来越多地应用差异构造方法。差异化构造方法允许根据要求对部件形状、制造、分离和连接工艺进行特定设计区域的调整。为了开发设计和评估方法和必要的模型，回答了以下研究问题：FF 1：如何以基于模型的方式评估分型面和接合面的位置，同时考虑到要求、部件功能以及制造和接合过程的限制？FF2：如何记录连接技术对功能相关部件性能的影响，并在分型线定义中具体使用和评估？FF3：以螺纹成型螺钉为例，如何将增材制造的潜力用作连接区设计中的组件连接？FF4：如何以机器可读的形式呈现关于连接过程的影响参数、有效机制以及限制和特性的研究结果？FF5：通过作用机制链接的整个系统的基于图形的表示是否可以以计算机辅助的上下文敏感方式用于增材制造？提供模型和方法以使得增材制造能够用于具有整体评估的大型部件。切割和连接的同等评估实现了资源节约的增材制造，并确保了增材制造部件的功能。为了能够有条不紊地支持评估复杂的组件，原型的上下文敏感的数字支持产品开发是通过一个数据库和一个适应的图形进行测试。

The aim of this project is to develop a method for the separation of large-volume components for additive manufacturing based on the differential design and the subsequent joining. Bolted joints are suitable as a representative joining technology in additive manufacturing because they are a widely used and well understood joining method. The accessibility and design of the joining zone represents a challenging use case for the method to be elaborated. Powder bed-based laser beam melting of the lightweight alloy AlSi10Mg is used as an additive manufacturing process, for which the applicant has a great deal of process knowledge. Through the design method analysis of both the L-PBF process and the process steps in bolting, the transferability of the developed method to other joining technologies is achieved. A single demonstrator will be dispensed with and instead several user-specific case studies will be used for the development of a database. In addition to the integral construction method, the differential construction method is to be increasingly applied in order to fulfill even contradictory requirements for a component. The differential construction method allows the design-zone-specific adaptation of component shape, manufacturing, separation and joining processes to the requirements. In order to develop the design and evaluation method and the necessary models, the following research questions are answered: FF1: How can the location of parting and joining surfaces be evaluated in a model-based manner, taking into account requirements, component functions, and restrictions from manufacturing and joining processes? FF2: How can the influence of the joining technology on the functionally relevant component properties be recorded, specifically used and evaluated in the definition of the parting line? FF3: How can the potentials of additive manufacturing be used as a component connection in the design of the joining zone using the example of thread-forming screws? FF4: How can the findings on the influencing parameters, effective mechanisms as well as restrictions and properties of the joining processes be presented in a machine-readable form? FF5: Can a graph-based representation of the overall system linked by mechanisms of action be used in additive manufacturing in a computer-aided, context-sensitive manner? Models and methods are provided to enable additive manufacturing to be used for large components with holistic evaluation. The equal evaluation of cutting and joining enables resource-saving additive manufacturing and ensures the functions of the additively manufactured component. In order to enable a methodically supported evaluation for complex components, a prototype of a context-sensitive digital support for product development is to be tested by means of a database and an adapted graph.