Lightweight Construction Summit 2021 Wurzburg
Kasım 24, 2021
Hafifletilmiş Konstrüksiyon Zirvesi – 2021 Würzburg – Hafifletilmiş malzeme yapımı üretiminde üç yeni yaklaşım hakkında bilgi almak için aşağıdaki linklere tıklayınız.
Simulating direct laser melting mathematically, building hybrids at minimal cost and “on-the-fly” injection molding: at the “Automobil Industrie Leichtbau-Gipfel” speakers from Magma, SGL Technologies and Anybrid described their approaches to material processing.
Application of plastic elements to a pipe structure – in the process of laser tape winding. The process comes from the Dresden company Anybrid.
With the right material, lighter components can be constructed; or implement new designs. At the lightweight construction summit, Horst Bramann from Magma explained the joint research project “Customat3D”, which deals with highly functional, diverse structural components in the automotive industry. Here, developers and end users work together to further develop materials, processes and simulations for lightweight components from additive manufacturing. The users of the components are Edag and Daimler.
In his lecture, Bramann discussed, among other things, the virtual assessment. He made a distinction between the digital shadow, a copy of reality; and the digital twin: “a forward-looking digital avatar”. This can move independently of reality and thus makes it possible to try things out. According to Bramann, the digital twin is more suitable for monitoring processes and product parameters or for comparing parameters.
Horst Bramann described in detail a plane model that shows the path from the powder to the component. This includes calculating the thermal conductivity of the powder used for additive manufacturing and modeling the layer structure – with a view to temperatures, strains and stresses. He also gave an insight into heat treatment; and how strain rates and stresses affect the components; and presented the first partial results of the project: for example, to determine material-specific data and the models used.
Hybrid components at minimal cost
Michael Kropka from SGL Technologies presented the second approach in the “Materials” session. His topic: “MAI HybCar” – generic vehicle underbody made of metal / CFRP hybrid with minimal lightweight construction costs and a high degree of automation in production. “MAI” stands for “Munich, Augsburg, Ingolstadt”, as moderator Heinrich Timm explained. Timm was head of the lightweight construction center at Audi and is currently a member of the board of directors of Carbon Composites e.V. and Carbon Composites United e.V.
Michael Kropka beschrieb in seinem Vortrag „die intelligente Kombination thermoplastischer Verbundwerkstoffe mit Stahlwerkstoffen“. Hintergrund: Von Plattformkonzepten werden heute etliche Derivate abgeleitet.
These platforms are usually designed in such a way that they can withstand the maximum expected load level. With many derivatives, this leads to oversized components and thus to excessive heights of the vehicles. “Especially when an expensive lightweight material such as carbon is used, oversizing is usually not worthwhile,” said Kropka. Carbon should only be used if the specific load level requires a higher resistance of the material used.
A tool kit for components with varying load requirements
With the “HybCar” concept, underbody components with varying load requirements are to be created with a single set of tools. The core of the process is the hybridization of the circuit board (metal / thermoplastic CFRP). This combines the forming, joining and consolidation of the polyamide 6-based fiber composite material in one process.
The local reinforcement with fiber composite materials makes it possible to reduce the sheet steel thickness from 2.5 mm to 0.7 mm; and thus to build the entire vehicle floor less high. In addition, thanks to the flexibility in the thickness of the fiber composite insert, the floor assembly can be designed and scaled as required. In the project, the front footwell gained over 18 millimeters in height.
“The weight of the underbody component fell by over ten kilograms compared to the benchmark,” said Kropka, “around 40 percent.” A fully automated production process also reduces the cycle time for production to less than 90 seconds. When asked about a recycling concept, Michael Kropka explained that “that was not part of the project, but the composite and sheet steel can be separated”.
“On-the-fly injection molding”
Michael Krahl, Managing Director of the Dresden-based company Anybrid, gave his lecture the distinctive title “Injection molding learns to fly”. Krahl described the current status, “Injection molding is often used for material combinations, for example in metal processing, thermoforming or extrusion. The systems are at the center of production. Why can’t we combine these two construction methods directly? ”, Krahl led on to the core of his lecture.
His company has developed “Robin” for this, “Robotized Injection Molding”, a movable injection molding machine. It consists of an injection unit, an injection molding tool and a lightweight C-frame – in the example, the system was mounted on a robot arm. The clearest advantage: It can be integrated into existing process lines.
Functional elements can be applied locally to large component structures, for example, or assemblies can be functionalized. “With our system we want to get into other processes,” said Krahl, describing the goal. Combinations of materials are conceivable, for example wood / plastic, metals, steel and aluminum. “This can make completely new products possible that could not be implemented otherwise.” A specific example that Michael Krahl showed was the application of plastic elements to a pipe structure – in the process of laser tape winding.
Dr. Götz Hartmann , Executive Manager | MAGMA GmbH
Dr. Michael Krahl Managing Director | ANYBRID GmbH
Dr. Michael Kropka, Team Lead New Application Technologies | SGL Technologies GmbH
The »Automobil Industrie« lightweight construction summit 2021 in Wurzburg is the top-class network event for and with pioneers of lightweight construction. The conference forms the ideal platform to discuss the essential importance of the key technology lightweight construction for the mobility of the future as well as cross-sectoral for environmental and climate protection.