Design for Additive Manufacturing and for Machining in the Automotive Field
High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-buil...
| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-08-01
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| Series: | Applied Sciences |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2076-3417/11/16/7559 |
| _version_ | 1797524728132403200 |
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| author | Elena Bassoli Silvio Defanti Emanuele Tognoli Nicolò Vincenzi Lorenzo Degli Esposti |
| author_facet | Elena Bassoli Silvio Defanti Emanuele Tognoli Nicolò Vincenzi Lorenzo Degli Esposti |
| author_sort | Elena Bassoli |
| collection | DOAJ |
| description | High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced. |
| first_indexed | 2024-03-10T09:01:29Z |
| format | Article |
| id | doaj.art-8631d3a2b1c1458aa226d045fb505d11 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T09:01:29Z |
| publishDate | 2021-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-8631d3a2b1c1458aa226d045fb505d112023-11-22T06:43:28ZengMDPI AGApplied Sciences2076-34172021-08-011116755910.3390/app11167559Design for Additive Manufacturing and for Machining in the Automotive FieldElena Bassoli0Silvio Defanti1Emanuele Tognoli2Nicolò Vincenzi3Lorenzo Degli Esposti4Department of Engineering “Enzo Ferrari” (DIEF), University of Modena and Reggio Emilia, Via P. Vivarelli, 10, 41125 Modena, ItalyDepartment of Engineering “Enzo Ferrari” (DIEF), University of Modena and Reggio Emilia, Via P. Vivarelli, 10, 41125 Modena, ItalyDepartment of Engineering “Enzo Ferrari” (DIEF), University of Modena and Reggio Emilia, Via P. Vivarelli, 10, 41125 Modena, ItalyDepartment of Engineering “Enzo Ferrari” (DIEF), University of Modena and Reggio Emilia, Via P. Vivarelli, 10, 41125 Modena, ItalyMetal Additive Research Centre, HPE s.r.l., Via R. Dalla Costa, 620, 41122 Modena, ItalyHigh cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced.https://www.mdpi.com/2076-3417/11/16/7559additive manufacturingdesign guidelinestopology optimizationlaser-based powder bed fusiondesign methodology |
| spellingShingle | Elena Bassoli Silvio Defanti Emanuele Tognoli Nicolò Vincenzi Lorenzo Degli Esposti Design for Additive Manufacturing and for Machining in the Automotive Field Applied Sciences additive manufacturing design guidelines topology optimization laser-based powder bed fusion design methodology |
| title | Design for Additive Manufacturing and for Machining in the Automotive Field |
| title_full | Design for Additive Manufacturing and for Machining in the Automotive Field |
| title_fullStr | Design for Additive Manufacturing and for Machining in the Automotive Field |
| title_full_unstemmed | Design for Additive Manufacturing and for Machining in the Automotive Field |
| title_short | Design for Additive Manufacturing and for Machining in the Automotive Field |
| title_sort | design for additive manufacturing and for machining in the automotive field |
| topic | additive manufacturing design guidelines topology optimization laser-based powder bed fusion design methodology |
| url | https://www.mdpi.com/2076-3417/11/16/7559 |
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