DE102017002581B3 - Method for producing a component - Google Patents

Abstract

The invention relates to a method for producing a component in which by means of a computer-aided simulation program in a first construction step in dependence on constructive boundary conditions, including an available component space (BR) and at least one load case and component storage conditions, an ideal load path (L). is determined by the component space (BR), based on which a first component model (M) is completely generated from solid material. According to the invention, the first component model (M) is divided into at least one first component zone (V) in the load case of high force density and in at least one second component zone (V) in the load case with low force density. In the second construction step, a second component model (M) is furthermore generated, in which the first component zone (V) is replaced by a three-dimensional, framework-like framework (13) with hollow structure (16) with high force density, and the second component zone (V). is replaced with a low power density omitting component material by a material clearance (19).

Description

The invention relates to a method for producing a component according to the preamble of claim 1 and a component according to claim 6.

The topology of a mechanical component is often improved with the aid of computer-aided optimization methods. The finite element method is used as the standard tool in component simulation, which is a numerical method for solving partial differential equations, and / or mechanical equilibrium relations. The aim of such component optimization is to find a load-appropriate material distribution in the component, while at the same time the component model should have the lowest possible component weight. By way of example, the topology optimization method used in industry is based on the so-called SIMP (Solid Isotropic Microstructure with Penalization) approach. This mathematical approach uses derivation methods within sensitivity analyzes to modify the design variables according to a normalized density. The result of this process are so-called 0-1 material distributions, that is, the presence or absence of material at grid points that are interpretable as component designs. Exemplary is on the DE 103 47 786 A1 or on the DE 10 2014 220 868 A1 directed.

In addition, a computer-aided simulation program is known, with which a component model can be generated, which has a so-called lattice structure in the available component space in which tetrahedra are networked with each other, whose edges are replaced by thin rods.

The object of the invention is to provide a method for producing a component, which has a reduced component weight with increased component rigidity in comparison to the prior art.

The object is solved by the features of claim 1 or 6. Preferred embodiments of the invention are disclosed in the subclaims.

According to the invention, a conventional, classical topology optimization is first carried out with the aid of a computer-aided simulation program in a first construction step. In this case, an ideal load path through the component installation space is determined as a function of constructive boundary conditions, that is, inter alia, an available component installation space and at least one load case as well as component storage conditions. On the basis of this, a first component model is completely generated from solid material in the first construction step. Subsequently, in a second construction step, the first component model is subdivided into at least one first component zone with a high force density in the load case and into at least one second component zone with a low force density in the load case. Subsequently, a second component model is generated in which the first component zone is replaced with high power density by a three-dimensional, truss-like framework with hollow structure. This framework can be influenced by the power flow in its dimensions (diameter). By contrast, the second component zone with low power density is completely replaced by a material clearance, omitting component material.

A force flow or load path is understood to be the path of a force and / or a moment in the component from the point of application (point of introduction of force) to the location of the force discharge, at which these are absorbed by a reaction force and / or a reaction moment. The force density results from the force introduced into the component with respect to an area (i.e., area force density) or to a volume (volume force density). The area force density is also called mechanical stress.

Due to the combination of the conventional classical topology optimization, which is carried out in the first construction step, with the provided in the second construction step lattice structure (that is, the framework), compared to the above prior art, by an exemplary 40% reduced component weight may result, and Although with the same component stiffness or even in an example By 12% increased component stiffness.

The second component model generated in the second construction step forms the basis for a subsequent production step. In the manufacturing step, a 3D metal printing method is preferably used which, on the basis of the above second component model, produces the actual component, namely in the same material and / or in one piece.

In a development of the invention, at least one third component zone can be defined in the second construction step at a force input or output point of the component, for example a fastening eye of a chassis link, in which a bearing can be used for articulation on a wheel carrier or on the vehicle body. The third component zone is preferred - in contrast to the first and second component zone of the second component model - constructed of solid material.

In a further technical implementation, a fourth component zone in the component model can additionally be defined in the second construction step, which corresponds to a closed-surface component outer skin made of solid material. In this case, the second component model has a completely or at least partially completely closed outer surface, which completely envelopes or covers the inner three-dimensional framework-like framework. Alternatively, the framework can also "grow out" of the shell.

The bars of the three-dimensional, truss-like framework of the component or the second component model can converge material-force and / or in one piece at force-conducting, in particular inner nodes. In addition, the rods can pass on to other force-conducting, in particular outer nodal points of uniform material and / or in one piece into the third or fourth component zone of the component or of the second component model constructed of solid material. With regard to a perfect force transmission at the outer nodes, it is preferred if the rod cross-section is widened at the outer node.

The invention is applicable to the manufacture of any component which has at least one three-dimensional truss-like framework. In the following special vehicle components are highlighted, which are produced in the process according to the invention using 3D metal printing process: Thus, the component may be a suspension arm for a two-lane vehicle, in a vehicle transverse direction at least one vehicle articulation An attachment eye for a bearing connection to a Having a vehicle wheel-carrying wheel carrier. In contrast, the suspension control arm can have at least one vehicle-internal articulation point another attachment eye for a bearing connection to the vehicle body. The two fastening eyes are preferably to be considered as force input or output points with strongly increased load density in the load case. Against this background, the attachment eyes are made of a solid material, i. not as a framework, executed. In contrast, running between the two fastening eyes handlebar sections is designed as a framework. It is preferred if the framework is covered on the outside, in particular completely over the entire surface, by a material outer skin formed from solid material in order to protect the inner framework from external mechanical influences, e.g. Rockfall, protect.

In a further embodiment variant, the component may have an inner framework, which is enveloped on the outside by a closed outer skin. In this case, the hollow structure of the framework for a resource management can be used. By way of example, the operating medium may be a coolant or the like, which is guided from a resource inlet formed in the outer skin to a component outlet of the component. In a technical realization, the component may be a rim with a radially inner hub body and a radially outer rim base, which are connected to each other via a spoke portion. At least the rim well as well as the spoke section, possibly also the hub body, can be constructed from an inner framework that is enveloped in a fluid-tight manner by a solid-material outer skin. In this case, the hollow structure of the framework can be used for air duct, in which the air from an air valve (ie the resource inlet), the framework and an air outlet formed in the rim well into the tire interior of a mounted on the rim tubeless Tire is passed. In this case, the air valve can be positioned independently of the rim base. Preferably, the air valve can be positioned centrally in the vicinity of the hub body. In such a centric arrangement of the air valve, a tire imbalance is substantially reduced.

Alternatively, the hollow structure of the framework of the component at least partially or completely filled with a foam material to possibly reduce a sound transmission or to improve the acoustic properties of the component.

Hereinafter, embodiments of the invention are described with reference to the accompanying figures.

• 1 einen im erfindungsgemäßen Verfahren hergestellten Fahrwerkslenker;
• 2 und 3 jeweils Schnittansichten entlang der Schnittebenen A-A und B-B aus der 1;
• 4 bis 6 jeweils Ansichten entsprechend der 2, die die Konstruktionsschritte zur Herstellung des in den 1 und 2 gezeigten Fahrwerkslenkers veranschaulichen;
• 7 eine Fahrzeugfelge, die mit dem erfindungsgemäßen Verfahren hergestellt ist; und
• 8 eine vergrößerte Schnittdarstellung eines weiteren Bauteils, in dem die Hohlstruktur des Stabwerks mit einem Schaum gefüllt ist.

Show it:

• 1 a suspension link manufactured in the method according to the invention;
• 2 and 3 each sectional view along the cutting planes AA and BB from the 1 ;
• 4 to 6 each views according to the 2 that describe the design steps for making the in the 1 and 2 illustrated suspension link illustrate;
• 7 a vehicle rim, which is produced by the method according to the invention; and
• 8th an enlarged sectional view of another component in which the hollow structure of the framework is filled with a foam.

In the 1 is a realized as a wishbone suspension arm 1 shown, which is installed in a mounting position, not shown in the suspension of a two-lane motor vehicle. The suspension handlebar 1 is via a vehicle outside pivot point A1 on one, a vehicle wheel bearing Wheel carrier steerable and at two vehicle-internal articulation points A2, A3 articulated to a vehicle body of the vehicle. The articulation points A1, A2 and A3 are in the 1 exemplified realized as a rubber-metal bearings, which in a vehicle outer mounting eye 5 as well as in vehicle-internal fastening eyes 7 can be used. The Indian 1 shown suspension arm has a in the 1 in the vehicle longitudinal direction x aligned longitudinal strut 11 on which the two vehicle interior fixing eyes 7 connects with each other. In addition, the two vehicle inner mounting eyes 7 over cross struts 9 with the vehicle outside attachment eye 5 connected.

In the 2 is the material structure of the longitudinal strut 11 represented the suspension control. The material structure of the two cross struts 9 can be realized in a similar way: Thus, the longitudinal strut 11 an inner three-dimensional, truss-like framework 13 on that in the 3 thin bars 15 having, in a hollow structure 16 converge at kraftleitenden inner nodes K1 material uniformly and / or in one piece. The bars 15 can simulate the course of interconnected tetrahedral edges.

The framework 13 is in the 2 on the outside of a component outer skin 17 completely encased, wrapped or covered in solid material. In addition, the hollow cylindrical attachment eye is also 7 made of a solid material. Like from the 3 shows, are the bars 15 of the framework 13 at kraftleitenden outer nodes K2 material uniform and integral to the hollow cylindrical mounting eye 7 tethered. In order to achieve a perfect force transfer at the outer nodes K2 at a component load, the rod cross-sections 18 of the bars 15 widened conically at the outer nodes K2.

The in the 1 to 3 shown suspension arms can be constructed by means of a computer-aided simulation program and then produced in a manufacturing step material uniformly and in one piece in a 3D metal printing process. The design steps required for this are based on the following 4 to 6 Thus, according to the 4 initially in a first construction step, an available component space BR and at least one load case and handlebar storage conditions set in the simulation program. On this basis, in the simulation program in the 4 indicated ideal load path L determined by the component space BR. On the basis of the ideal load path L, the computer-aided simulation program generates a first component model M ₁ (FIG. 4 ) made entirely of solid material, taking into account the above design constraints.

Subsequently, in a second construction step ( 5 ) a division of the first component model M ₁ in different component zones V ₁ to V ₄ , wherein the classification of the component zones V ₁ and V _{2 is carried out} on the basis of expected in the load case force densities. Exemplary are in the 5 in the component model M _1, a first component zone V _{1 is entered} with a high force density in the load case, which is formed in cross-section like a downwardly open U-profile. Their profile leg limit a second component zone V ₂ with low power density in the load case. Moreover, in the 5 defines a completely constructed of solid material component zone V ₃ , namely at the attachment eyes 5 . 7 which act as force input or output points in the load case. Furthermore, in the 5 defines a fourth component zone V ₄ , which is also made of solid material executable and a closed-surface component outer skin 17 forms.

In the second construction step is in the 6 - Forming the second component model M ₂ - the above-defined first component zone V ₁ in the load case high power density through the three-dimensional, truss-like framework 13 replaced, while the second component zone V ₂ with low power density omitting component material completely through a material clearance 19 is replaced. On the basis of in the 6 indicated second component model M ₂ , a manufacturing step is carried out in which in the 3D metal printing process in the 1 shown suspension arm is made.

Alternative to 5 and 6 can from the fourth component zone V ₄ (ie from the closed-surface component outer skin 17 in the 6 ) additionally in the 6 Dashed lines indicated framework 13 ' (ie a lattice structure) "outgrow". Preferably, this additional outer lattice structure in the material-free space 19 ( 6 ) protrude.

The following is based on the 7 A second embodiment of the invention shown in which the component is a vehicle rim. This has according to the 7 a radially outer rim base 21 on, that over a spoke section 23 with a radially inner hub body 25 connected is. The rim bed 21 carries only a roughly indicated tubeless vehicle tires 27 , In the 7 has the hollow cylindrical hub body made of a solid material 25 in flight to the axis of rotation a central opening 28 on, by a centering screw is feasible. In addition, the hub body 25 circumferential rims 26 on.

In contrast to the hub body 25 are in the 7 the rim bed 21 and the spoke section 23 not entirely of solid material, but of an inner framework 13 built up. The inner framework 13 is on the outside by an outer skin 17 completely enclosed surface wrapped .. In this way, the hollow structure 16 of the framework 13 to serve the air duct, by means of the air from an air valve 29 about at least one in the rim 21 trained air outlet 31 in the tire interior 33 to be led. That way, the air valve can 29 independent of position from the rim 21 be positioned, and in particular in the 7 shown centric arrangement, whereby a tire imbalance is reducible.

In the 8th is roughly schematically shown a further material structure of a component according to the invention. The material structure has a framework 13 on, which is connected to outer nodes K2 on a formed of solid material component zone. The hollow structure in the framework 13 is in the 8th by means of a foam material 35 filled, whereby the component is given a favorable acoustics.

Alternatively, the component may also be, for example, an internally ventilated brake disk in which the hollow structure 16 of the framework 13 the brake disc interior ventilation supported.

Claims (9)

Method for producing a component in which, by means of a computer-aided simulation program, in a first construction step, depending on constructive boundary conditions, including an available component space (BR) and at least one load case and component storage conditions, an ideal load path (L) through the component Building space (BR) is determined, based on which a first component model (M ₁ ) is completely generated from solid material, characterized in that in a second construction section, a division of the first component model (M ₁ ) in at least a first component zone ( V ₁ ) takes place in the load case of high force density and in at least one second component zone (V ₂ ) with low force density in the load case, and that in the second design step a second component model (M ₂ ) is generated, in which the first component zone (V ₁ ) with high power density by a three-dimensional, truss-like framework (13) with hollow structure (16 ) is replaced, and the second component zone (V ₂ ) with low power density, omitting component material by a material-free space (19) is replaced. Method according to Claim 1 , characterized in that the component on the basis of the second component model (M ₂ ) in a manufacturing step is made of the same material and / or in one piece. Method according to one of the preceding claims, characterized in that in the second construction step at a force input and / or -ausleitungspunkt (5, 7) of the component model (M ₂ ), a third component zone (V ₃ ) is defined in which a bearing can be used for articulation on a wheel carrier or on a vehicle body, wherein the third component zone (V ₃ ) is a solid material zone. Method according to Claim 1 . 2 or 3 , characterized in that in the second construction step on a component outside of the component model (M ₂ ) a fourth component zone (V ₄ ) is defined from solid material, which corresponds to a component outer skin (17), so that the second component model (M ₂ ) has an outer skin surface which is closed at least partially over the entire surface and which covers the inner three-dimensional framework-like framework (13). Method according to one of the preceding claims, characterized in that the rods (15) of the three-dimensional, truss-like framework (13) of the second component model (M ₂ ) converge materially and / or integrally at force-conducting nodes (K1), and / or the rods (15) at force-conducting nodes (K2) material uniformly and / or in one piece in the solid material component zones of the component or the second component model (M ₂ ) go over. Component, produced by a method according to one of the preceding claims, wherein the component has at least one completely constructed of solid material component zone and a three-dimensional truss-like framework (13), and wherein the component is a suspension arm for a two-lane vehicle in a vehicle transverse direction (y ) at at least one vehicle-external articulation point (A1) a fastening eye (5) for a bearing connection to a, a vehicle wheel (27) carrying wheel carrier and at least one vehicle-internal articulation point (A2, A3) another mounting eye (7) for a storage Connection to a vehicle body, and wherein the fastening eyes (5, 7) are designed as solid material component zones, while a handlebar section (7, 9) between the fastening eyes (5, 7) as a framework (13) with a hollow structure (16) is, and wherein the framework (13) on the outside of a closed-surface material outer skin (17) is covered. Component after Claim 6 , characterized in that the component has an inner truss (13), which is coated on the outside by a realized as a component zone outer skin (17), and that the hollow structure (16) of the truss (13) is usable for a resource management at a resource is conducted from a resource inlet (29) to a resource outlet (31). Component after Claim 7 , characterized in that the component is a rim with a radially inner hub body (25) and a radially outer rim base (21), which are connected to each other via a spoke portion (23), and that at least the rim base (21) and the spoke portion (21). 23) is constructed from an inner framework (13) which is enveloped by a closed-surface outer skin (17) formed from solid material, and that the hollow structure (16) of the framework (13) serves for the air duct, in the air from an air valve ( 29) is guided through the hollow structure (16) of the framework (13) via at least one air outlet (31) formed in the rim base (21) into a tire interior (33). Component according to one of Claims 6 . 7 or 8th , characterized in that the hollow structure (16) of the framework (13) is at least partially filled with a foam material (35).

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