When manufacturing with AM in the automotive industry make sense? MAGDALENA ŻUK, 205222 WHERE WE USE AM? Limitless, but is it true, when we care about...
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When manufacturing with AM in the automotive industry make sense? MAGDALENA ŻUK, 205222
WHERE WE USE AM?
Additive Manufacturing is the process of making a product by adding layers in a relatively efficient way, such that there is little waste or reduction of materials.
AM application is limitless.
Early use of AM in the form of Rapid Prototyping focused on preproduction visualization models.
More recenty, AM is being used to fabricate end-use products in: • aircraft, • dental restorations,
• medical implants, • automobiles,
• and even fashion products.
Limitless, but is it true, when we care about production cost?
AM IN AEROSPACE INDUSTRY Aerospace industry is one of these areas, when using AM in manufacturing is profitable.
There are lots of aerospace applications for Additive Manufacturing (AM). The aerospace industry is characterized by:
short production runs of expensive parts
In that scenario, AM can lead to a lower overall cost when compared to the cost of expensive tooling for a conventional subtractive manufacturing process.
AM IN AUTOMOTIVE INDUSTRY
AM techniques in the automotive industry have been primarily focused on prototyping to increase research and development efficiency and reduce product-to-market time delivery. …rather than on actual manufacturing.
Used as rapid prototyping, AM shortens design validation and implementation cycles and helps release new components versions quickly.
MANUFACTURING WITH AM IN AUTOMOTIVE?
YES or NOT?
But are there applications for AM as an alternative production method?
Can AM allow manufacturers to build functional components in a cost effective way where conventional manufacturing techniques actually cost more?
The answer appears to be “yes”, particularly when the process allows manufacturers to integrate or combine components in a single step, such as when surface textures, complex inner channels and meshes are involved. AM techniques can also make economic sense for customized highvalue car components.
EXAMPLES IN AUTOMOTIVE INDUSTRY
1. CENTER
HOUSING IN TURBOCHARGER (IN DIESEL ENGINES)
improving combustion efficiency and reducing fuel consumption with SLM technology
2. ELECTRICAL
CONNECTORS & WIRING GROMMETS
complicated shapes in short time with CLIP technology
1. CENTER HOUSING IN TURBOCHARGER Diesel engines are often turbocharged and aftercooled to enhance the engine's power capacity and its fuel economy. A turbocharger is an assembly of different components: - compressor housing (1),
- compressor impeller (2), - shaft (3) & bearing system (4), - center housing (5), - turbine impeller (6) & turbine housing (7)
1. CENTER HOUSING IN TURBOCHARGER Turbochargers are exposed to extremely high thermal and pressure stress. Typically, the center housing integrates inner channels that supply bearings with pressurized engine oil for lubrication. Internal water-cooling passages are designed into the housing to keep the lubricant cool and in a liquid state.
1. CENTER HOUSING IN TURBOCHARGER conventional technology: SAND CASTING is a metal casting process
characterized
by
using
sand as the mold material.
..and then post-machined to create the internal cooling and lubrication channels. Center housing (in conventional way) was made from cast iron.
1. CENTER HOUSING IN TURBOCHARGER AM technology:
SLM
„Selective Laser Melting” is an AM process that uses 3D CAD data as a digital information source and energy in the form of a high-power laser beam, to create 3-dimensional metal parts by fusing fine metal powders together.
1. CENTER HOUSING IN TURBOCHARGER
SLM offers maximum design freedom for complex and light rigid components. Design engineers can develop more complex internal channels in the center housing to improve the cooling and lubrication system. efficient cooling (of shaft and bearings) larger RPM values & air flow to the cylinders improving turbocharger efficiency reducing fuel consumption & temperature reducing CO2 emissions & increase turbocharger lifespan
1. CENTER HOUSING IN TURBOCHARGER
Another advantage to the AM process is that the housing can be made of steel 316L (instead of conventional cast iron), which leads to improved strength.
Compared with sand casting, a center manufactured by AM requires less post processing.
SLM technology also eliminates waste material and saves up to 50 % of the end design volume with by avoiding fusion in non-functional areas.
housing
2. ELECTRICAL CONNECTORS & WIRING GROMMETS
WIRING GROMMET is an element allowing for the cable putting through the housing.
ELECTRICAL CONNECTOR is an insulating device, designed to connect power cables (of low voltage).
2. ELECTRICAL CONNECTORS & WIRING GROMMETS conventional technology: is a manufacturing process for producing parts by injecting material into a mould.
INJECTION MOULDING
2. ELECTRICAL CONNECTORS & WIRING GROMMETS AM technology:
CLIP
„Continuous Liquid Interface Production”
is a photochemical process that makes it possible to produce parts with excellent mechanical properties and surface finish, using light-curing resins.
2. ELECTRICAL CONNECTORS & CABLE GLANDS
This new 3D printing process makes complex shapes that can’t be made by mould injection.
We haven’t layers – so our part is stronger.
Super-fast process time.
Interesting resins offer, which have properties better than what is currently on the market.
SUMMARY Disadvantage of conventional manufacturing techniques is that they limit design freedom. As a result, components are always a compromise between function and feasibility. AM technology frees up development from these constraints, it only applies material where it is functionally necessary.
In addition, using AM we can reduce the mass of moving and/or accelerating components is especially important since this directly increases energy efficiency.
SUMMARY Nowadays the automotive industry is focused on: energy-efficient reducing
engines,
CO2 emissions
increasing
demand for customer-specific components in serial production.
Additive Manufacturing is the solution here: it enables cost-efficient manufacture of individualized mass products.
THANK YOU FOR YOUR ATTENTION