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

本项目的目的是开发一种基于差异化设计和后续连接的加法制造中大容量部件的分离方法。螺栓联接是一种应用广泛且广为人知的联接方法，适合作为添加剂制造中的一种典型联接技术。连接区的可达性和设计对于将要详细说明的方法来说是一个具有挑战性的用例。采用粉末床基激光熔炼AlSi10 Mg轻质合金作为添加剂制造工艺，申请人对此具有丰富的工艺知识。通过对L-PBF工艺和螺栓连接工艺步骤的设计方法分析，实现了该方法对其他连接技术的可移植性。将不再使用一名演示员，而是使用几个针对具体用户的案例研究来开发一个数据库。除了整体施工法，差分施工法也将越来越多地应用，以满足甚至是矛盾的构件要求。不同的施工方法允许特定设计区对部件形状、制造、分离和连接过程进行调整，以满足要求。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：FF1：如何以基于模型的方式评估分型面和连接面的位置，同时考虑到要求、部件功能以及制造和连接过程的限制？FF2：如何在分型线的定义中记录、具体使用和评估连接技术对功能相关零部件特性的影响？FF3：以螺纹成形螺丝为例，在连接区的设计中，如何利用添加剂制造的潜力作为部件连接？FF4：关于连接过程的影响参数、有效机制以及限制和特性的调查结果如何以机器可读的形式呈现？FF5：通过作用机制连接起来的整个系统的基于图形的表示能否以计算机辅助的、上下文敏感的方式用于加法制造？提供了模型和方法，以使加法制造能够用于具有整体评价的大型部件。切割和连接的平等评估使资源节约的添加制造成为可能，并确保添加制造的部件的功能。为了能够有条不紊地支持对复杂组件的评价，将通过数据库和调整后的图表来测试产品开发的上下文敏感数字支持的原型。

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.