Research, Educational and Other Activities at IMD

Transcription

1 D. Koutný Institute of Machine and Industrial Design Faculty of Mechanical Engineering Brno University of Technology

2 Outline Research activities Additive Manufacturing Intro Examples of Research Results Orthostics and Prosthestics Examples of Research Results Educational activities Other activities 1/25

3 Research in area of additive manufacturing of metal materials Selective Laser Melting Layer thickness: 50µm Max part bounding box: 280x280x350mm Materials: AlSi10Mg 316L TiAl6V4 2/25

4 Selective Laser Melting Process Large thermal stresses Liquid /solid phase volume difference Heat transmition from processed layer Supports optimization Strong connection with base platform Good heat flow 3/25

5 Main application areas of Additive Manufacturing Medical Custom made implants Structures for bone growth Biocompatible materials University of Applied Sciences and Arts Northwestern Switzerland FHNW Automotive High temperature applications Compressor wheels and housings Heat exchangers Aerospace Complex geometry parts Parts with high weight/stiffness ratio Topology optimized parts LayerWise EADS 4/25

6 Main research areas of Additive Manufacturing Material Research Product research Process Research Quality Control Simulation New Materials Design Rules Energy Consumption Product Certification Simulation of Parts Microstructure manipulation Bionic Structures Laser Development Process Certification Simulation of Processes Mechanical properties Light Weight Structures Process Tolerances Online Process Control Simulation of Materials Electric Properties Part Tolerances Reduction of Residual Stresses Standards Development Thermal Properties Recycling Costs Software Development Modified: Gausemeier, Klemp, Wall, Peter (DDMC 2014) 5/25

7 Dimensional accuracy process setup High inacuraccy of outher dimensions High surface roughness in Z direction Modification of process parameters Elimination of outher contours Outer size deviation within 0,2mm Internal features deviation within+- 0,05 mm 6/25

8 Dimensional accuracy results Accuracy of internal cylinders 7/25

9 Analysis of influence of process parameters on dimensional accuracy Variable parameters Laser Speed A E Contour mm.s -1 Volume mm.s -1 Laser Power W 8/25

10 Surface roughness analysis Arithmetic mean deviation of surface profile Ra 9/25

11 Material Homogenity Analysis GE v tome x L 240 Voxel size: 8,7 µm Pore size 0,05-0,8 mm 0,6 % defects in volume Example of µct analysis: original sample (left), reconstructed volume (middle), microscopic pore analysis (right). Kaiser, J.; Pantelejev, P. et al. unpublished. 10/25

12 Influece of Manufacturing Accuracy on Behaviour of Lattice Structures Optical Analysis of small beam samples Quality analysis of different angles Correction factors Alsi10Mg, 316L 11/25

13 Evaluation of Correction Factors by Mechanical Testing Testing samples with set of beams Tensile test without correction Tensile testing and evaluation ε [-] Tensile test with correction σ [MPa] σ [MPa] ε [-] 12/25

14 Development of augmentation for revision implat of knee joint Implementation of trabecular structure into Augmentation design Testing of manufacturability by SLM Testing of structure stiffness Obr.1 13/25

15 Development of orthotic and prosthetic components by AM Transtibial socket for first-equipment prosthesis Foot for low activity patients Adjustable deflection 14/25

16 Analysis of material properties of FDM plastics Dependence on part orientation Dependence on hatching strategy Anisotropic behaviour σ [MPa] Basic Fat Thin Basic Fat Thin * Basic * Fat * Thin Basic Fat Thin ε [-] *samples without posprocessing 15/25

17 Development of Ankle-Foot Orthosis by AM Custom Made specific geometry of patient body Contactless digitization Manufacturing using FDM technology ongoing process (nylon) 16/25

18 Development of transtibial prosthesis for in-line skating Determination of plantar /dorzal flexion angles Determination of prosthesis loadig during skating Manufacturing of experimental skating prosthesis 17/25

19 Recent and ongoing projects MIT [TIP] - Application of digital technologies for orthotic and prosthetic devices, Ing Corporation ( ) MEYS [EUREKA] - Hydrostatic Regenerative Module for Utility Vehicles, Bosch-Rexroth ( ) MEYS [OP R&DI] - Netme Centre ( ) MEYS [OP R&DI] - Netme Centre Plus ( ) ESA [LK Engineering+Thales Alenia Space+Brno University of Technology] HS Design of spacecraft components for additive manufacturing ( ) HS Development of ticket vending machine (2013) HS Ergonomics study of convection oven handle (2013) HS Reverse engineering of engine block (2013) HS Development of rooftop air conditioning unit ( ) 18/25

20 Submitted projects TAČR [Alfa] - Development and production of parts for automotive and high temperature aerospace applications using 3D laser additive technology GAČR [ST] - Design of advanced materials using selective laser melting 19/25

21 Publications Palousek, D.; Rosicky, J.; Koutny, D.; Stoklasek, P.; Navrat, T. Pilot study of the wrist orthosis design proces. Rapid Prototyping Journal. Vol. 20, 1. pp ISSN: Palousek, D.; Rosicky, J.; Koutny, D. Use of Digital Technologies for Nasal Prosthesis Manufacturing. Prosthetics and Orthotics International. ISSN print/issn online. Koutny, D., Palousek, D., Stoklasek, P., Rosicky, J., Tepla, L., Prochazkova, M., Krejci, P. The Biomechanics of Cycling with a Transtibial Prosthesis: A Case Study of a Professional Cyclist. International Journal of Medical, Pharmaceutical Science and Engineering Vol:7 No:12, 2013 Ilčík, J., D. Koutný, and D. Paloušek. "Geometrical Accuracy of the Metal Parts Produced by Selective Laser Melting: Initial Tests." Modern Methods of Construction Design. Springer International Publishing, /25

22 Publications in preparation Palousek, D.; Omasta, M.; Koutecky, T.; Bednar, J.; Effect of matte sprays on 3D optics measurement accuracy, Optics and Lasers in Engineering. Will be submitted. Koutny, D.; Vrana R.; Palousek, D. Influence of SLM manufacturing accuracy on mechanical properties of lattice structures. Rapid Prototyping Journal. Will be submitted. 21/25

23 Educational activities Fundamentals of Design (BS) CATIA, Pro/Engineer (MS) Plastic Prototypes and Rapid Prototyping (MS) Team Project (MS) Mechanical Design Project (MS) Engineering Project (MS) Erasmus coordination Project Oriented Learning coordination Guidelines, State Exams, Administrative of Mechanical Engineering Design study branch 22/25

24 7 th Pneumobile Competition Eger, Hungary Two teams with modified vehicles 23/25

25 3D Printing services 24/25

26 Thank you for your attention D. Koutný