Development of a topological optimised Hinge Arm through combination of ALM- and investment casting processes
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This document discusses the development of a topologically optimized hinge arm component through a combination of additive manufacturing and investment casting processes. It begins with an overview of Alcoa, describing its founding, global operations, and business groups. It then provides details on Alcoa's investment casting capabilities and facilities. The document presents a case study on redesigning an aircraft hinge arm component using topology optimization, additive manufacturing of patterns, and investment casting. The optimized design achieved a 47% weight reduction while meeting all stress and displacement constraints.
Development of a topological optimised Hinge Arm through combination of ALM- and investment casting processes
- 1. Alcoa Confidential Alcoa Power & Propulsion - Structural Castings
- 2. Alcoa Confidential Welcome Development of a topological optimised Hinge Arm through combination of ALM- and Investment Casting processes Rainer Sabisch APP Director Global Application Engineering
- 3. Alcoa Confidential About ALCOA Founded in 1888, after inventing process for making aluminum Global innovation leader in lightweight, high-performance metals, products, solutions 59,000 employees across 30 countries 2014 sales: $24 billion At-a-Glance Serving Several End Markets Aerospace Automotive Commercial Transportation Beverage Packaging Building and Construction Industrial Gas Turbines 3
- 4. Alcoa Confidential Downstream Engineered Products & Solutions Midstream Global Rolled Products Strategy Drive Share Gains through Leadership in product and process Innovation Power & Propulsion Fastening Systems & Rings Building & Construction Systems Forging & Extrusions Wheel & Transportation Bauxite mining Alumina refining Aluminum smelting Aluminum recycling Power generation Move down the refining cost curve Move down the smelting cost curve Drive growth through product innovation Reduce cost through process innovation Packaging Aerospace & Defense Automotive Consumer Electronics Industrial Operations 2014 Revenue: $6.0 Billion 2014 Revenue: $7.4 Billion 2014 Revenue: $10.3 Billion Upstream Global Primary Products ALCOA’s three Business Groups
- 5. Alcoa Confidential APP Structural Casting Location Map 2,331 employees (as of 02/28/15) Alcoa Power and Propulsion Structural Casting Facilities 1. Whitehall, MI USA (Titanium) 2. Hampton, VA USA (Titanium &Superalloy) 3. La Porte, IN USA (Superalloy) 4. Georgetown, Ontario, Canada (Aluminum) 5. Laval, Quebec, Canada (Aluminum) 6. Evron, France (Aluminum) 7. Gennevilliers, France (Superalloy) 8. Bestwig, Germany (Titanium & Aluminum) 9. Nantong, China (Aluminum) 2 1 3 4 5 76 8 9
- 6. Alcoa Confidential General Capabilities – Castings Superalloy Titanium Aluminum Aerospace engine components Aircraft structural components Military components Turbochargers Aerospace engine components Aircraft structural components Military components Aerospace engine components Aircraft structural components Military components Turbochargers Max length = L = 52 inch 1321 mm Max width = W = 52 inch 1321 mm Max height = H = 25 inch 635 mm Pouring weight = P = 700 lb 318 Kg HERO Premium & SOPHIA Casting
- 7. Alcoa Confidential Casting Processes Casting processes of metal-based materials Permanent pattern (devided mould) Without pattern Permanent mould Lost pattern (undevided mould) Lost mould Die casting Chill casting Continuous casting Sand casting Shell-mould casting Evaporative pattern casting Investment casting
- 8. Alcoa Confidential Investment Casting Process Shelling- and pouring process
- 9. Alcoa Confidential Investment Casting Benefits Optimized use of material Max. design freedom (undercuts) High level of precision Low wall thicknesses High mechanical properties Excellent material consistence Little weight Tooled or tool free manufacture (Rapid Prototyping)
- 10. Alcoa ConfidentialAlcoa Confidential Overview ALM-Technology (Polymer) SLS - Selective Laser Sintering (Powder) Models preferred for Al-Castings SLA – Stereolithography (Resin) Models preferred for Ti Castings Usability as Lost Pattern for the Investment Casting process Alcoa Confidential
- 11. Alcoa ConfidentialAlcoa Confidential Advantages / Limits of the RP-process Reduced lead times Reduced development cost Flexibility Identical mechanical properties as serial production Max. design freedom (undercuts) Part sizes up to 1500 x 1300 x 900mm Qualified processes Best prerequisite for topology optimisation Alcoa Confidential
- 12. Alcoa ConfidentialAlcoa Confidential What is Topology Optimization? Alcoa Confidential Body mass is distributed in an optimal way within a determined room Topology optimization is applied during the design phase Conditions of loads and connections are determined and these data are used to generate a FE (finite elements) model The result is a scraggy model which will finally be smoothed to form a CAD-model Targets: Cost and weight savings of monolithic investment castings!
- 13. Alcoa ConfidentialAlcoa Confidential Topology: Nature is the best inventor Alcoa Confidential The leaf is only 2 mm thick and 2 meters in diameter, but it can carry a human body of 50-60 kg weight. Giant Water Lily Source: Nachtigall, Blüchel: Das große Buch der Bionik
- 14. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Connecting component between aircraft fuselage and passenger door
- 15. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Target Weight Constraints – Max. 10 kg Displacement Constraints – Z-direction: 1,0 mm – XYZ-direction: 2,5 mm Material Constraints – E357 acc. to AMS4288 Rm: 310 MPa Rp0,2: 248 MPa A4: 2% Alcoa Confidential Weight: 11,6 kg Current Design
- 16. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Design Space Design Area Non-Design Area
- 17. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Mounting Parts
- 18. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Design Space Design Area Non-Design Area
- 19. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Topology Model
- 20. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential
- 21. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Iteration 1 – Single Split Direction Final Mass: 8,01 kg Max Stress: 359 MPa
- 22. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Displacement Load Case Displ. Tz Displ. Txyz Closed -0,754mm 1,763mm Position 1 -0,770mm 1,734mm Position 2 -0,780mm 1,713mm Open Gravity -0,740mm 1,975mm Iteration 2 – No Manufacturing Constraints Final Mass: 4,81 kg Max Stress: 319 MPa
- 23. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Transition into CAD-Model Final Mass: 6,14 kg
- 24. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Alcoa Confidential Summary Initial Design Goal Result Stress N/A N/A 319 MPa Displacement Z N/A <1,0mm <0,8mm Displacement XYZ N/A <2,5mm <2,0mm Weight 11,6kg <10,0kg 6,14kg Weight saving 5,46 kg = -47%
- 25. Alcoa ConfidentialAlcoa Confidential Case Study „Hinge Arm“ Al - Investment Casting
- 26. Alcoa Confidential Conclusion Rapid Prototyping Investment Casting Topology Optimisation 3 steps to an optimised design!