Institute of Engineering Design/CAD

Universitaet des Saarlandes
Prof. Weber
PO Box 15 11 50
D - 66041 Saarbruecken, Germany

Design and Optimisation of Ceramic Intermetallic Engine Parts and Process Parameters

WORKPACKAGE TITLE: 3.2 Powder Design Modelling STARTING DATE (Month #) 1 DURATION (Months) 36 Effort (MM) 20 OBJECTIVES

Simulation of the dry pressing process (first stage of manufacturing) of ceramic/intermetallic composite components; analyzing possibilities to simulate workpiece behaviour during sintering process (second stage of manufacturing).

DESCRIPTION OF WORK / TASKS

The work will be based on models and simulations from previous research activities in the field of dry-pressing of ceramic materials [Labi-95, LaWW-95, Labi-96]. In this project these models must be modified to incorporate composite powders (with different mechanical properties). More complex component and tool geometries (valves, turbine blades) have be examined. Also advanced manufacturing conditions (University of Karlsruhe) as well as improved knowledge on micro-scale or even atomistic effects (CalTech, Pasadena; Imperial College, London) created by other partners within this project will be incorporated into the models and simulations.

With respect to component design and manufacturing in practice possibilities and means of simulating the behaviour of the workpiece during the sintering process will be examined.

The results of the simulation will be fed back to the design of the components and tools and the definition of manufacturing processes and parameters suitable in practice. [Labi-95] Labisch, Susanna: Untersuchung des Kaltpressens pulverf”rmiger Stoffe mit Hilfe der Methode der Finiten Elemente unter besonderer Bercksichtigung der Trockenpressung von Sekundrkornmassen. Dissertation Universitt des Saarlandes, Saarbrcken 1995. Schriftenreihe Produktionstechnik, Band 11. [Labi-96] Labisch, Susanna: Simulation des Trockenpressens; Effiziente Verdichtung von Sekund r- kornmassen. Fachtagung ,Simulation mit der Finite-Element-Methode in Feinwerk- und Mikrotechnik", Mnchen 12.03.1996. Proceedings, Manuskript Nr. A-10. Institut fr Technologie- und Wissenstransfer an der Fachhochschule Mnchen e.V., Mnchen 1996. [LaWW-95] Labisch, Susanna; Weber, Christian; Werner, Horst: Investigation of the Stiffness of Individual and Agglomerated Granules by the Finite Element Method. ceramic forum international/Berichte der Deutschen Keramischen Gesellschaft 72 (1995) 9, p. 540-545.

DELIVERABLES

Models and simulations of the pressing of ceramic/intermetallic composite powders.

MILESTONES AND CRITERIA

Month 6: Definition of requirements for models and simulations (materials, properties, expected geometries, process parameters).

Month 12: Models and simulation results for pressing of simple (component and tool) geometries.

Month 24: Comparison of results with experimantal data, retune of models.

Month 30: Models and simulation results for pressing of practically relevant component geometries.

Month 36: Simulation-based process optimization (pressing); possibilities of simulating the behaviour of the workpiece during the sintering process.

INTERRELATION WITH OTHER WORKPACKGES

Processes and process parameters obtained from workpackages 1.2, 1.3, 3.1, 4.1 and 4.2; powder data obtained from 3.1; input for component and tool geometries obtained from 3.3 and 6; Micro-scale and atomistic effects obtained from 1.

Feedback of results to 3.1 (powder), to 4.1 and 4.2 (process-related), to 3.2 and 6 (design of components).

WORKPACKAGE TITLE: 3.3 Structure Design Optimization STARTING DATE (Month #) 7 DURATION (Months) 30 Effort (MM) 16 OBJECTIVES

Design of components (engine valves, turbine blades) with regard to the new materials and manufacturing processes; structural optimization of components; development of new design strategies and ways to transfer these into practical application; delivery and conversion of (3D) CAD- and FE-models within partnership.

DESCRIPTION OF WORK / TASKS

New materials and new manufacturing processes require modified design strategies and lead to different design results. To get the results of basic research activities into practice quickly it is necessary to develop appropriate methods and - where feasible - tools simultaneously. This will be done by actively designing experimental engine valves and turbine blades based on the inputs of the project partners concerning aging effects, atomistic simulation and tribology as well as processes and process parameters and using 3D-CAD equipment throughout.

Optimized shapes of the components will be elaborated based on own optimization software tools (CASOP, CATOP, [BWe-96, WeB-96, WeB-97, Br-98]) as well as commercial tools.

Based on appropriate equipment and special know-how obtained in a lot of industry- related projects [WeMu-95], as a "sideline" of this workpackage CAD- and FE-models (in different formats as necessary) for further macro-scale analysis as well as manufacturing of the valves can be supplied to all relevant partners (e.g. Imperial College, London; Universitat Politecnica de Catalunya, Barcelona; DaimlerChrysler, Stuttgart; Centro Ricerce Fiat, Torino). Also CAD- and FE-models delivered by project partners can be converted for further use by others.

[B r-98] B r, Thomas: Einsatz der Feature-Technologie fr die Integration von Berechnungen in die frhen Phasen des Konstruktionsprozesses. Dissertation Universit t des Saarlandes, Saarbrcken 1998. Schriftenreihe Produktionstechnik, Band 15. [B We-96] B r, Thomas; Weber, Christian: Development of an Easy to Use Shape Optimization Tool Based on FEM. 12th International Conference on CAD/CAM, Robotics and Factories of the Future 1996 (CARs & FOF `96), London/Groábritannien 14.-16.08.1996. Proceedings p. 672-678. [B We-97] B r, Thomas; Weber, Christian: Support in the Early Design Phase by Working with Intelligent Element Pairs which Simplify the Use of FEM. International Conference on Engineering Design 1997 (ICED 97), Tampere/Finnland 19.-21.08.1997. WDK 25: Proceedings of ICED 97 (ed. by A. Riitahuhta), Vol. 3, p. 231-234. Tampere University of Technology 1997. [WeB -96] Weber, Christian; B r, Thomas: CASOP - Ein einfach zu handhabendes Gestalt- optimierungswerkzeug, einsetzbar in den frhen Phasen des Konstruktionsprozesses. VDI- Fachtagung ,Informationsverarbeitung in der Konstruktion `96", Mnchen 22.-23.10.1996. VDI-Berichte Nr. 1289, p. 239-253. VDI-Verlag, Dsseldorf 1996. [WeMu-95] Weber, Christian; Muth, Michael: Transfer von Daten und Bausteinen beim CAD/CAM-Sy- stemwechsel - M”glichkeiten und Grenzen. VDI-Fachtagung ,CAD/CAM-Systemwechsel - ein Schritt ins Ungewisse?", Mnchen 19.-20.10.1995. VDI-Berichte Nr. 1216, S. 15-32. VDI-Verlag, Dsseldorf 1995.

DELIVERABLES

Optimized geometries for engine valves and turbine blades made from ceramic/intermetallic composite materials; design strategies; CAD- and FE-models for other partners.

MILESTONES AND CRITERIA

Month 9: Definition of functional requirements for components to be designed and optimized (engine valves and/or turbine blades; requirements of integration into engine system; performance requirements; required improvements compared to conventional solutions).

Month 12: Definition of material and manufacturing process requirements for components to be designed and optimized.

Month 18: First design of components finished; discussion with partners (industrial application, powder, processing, properties); definition of optimization goals and strategies.

Month 24: Optimization results; discussion with partners.

Month 30: End of component design phase; conclusions concerning design strategies; discussion with partners.

Month 36: Concepts and - if possible - first tools for the transfer of (design) knowledge into practical application.

Please note: Months are numbered with regard to the timetable of the whole project, not to this workpackage which only starts in month 7.

INTERRELATION WITH OTHER WORKPACKGES

Functional requirements obtained from workpackages within 6 and 2; material requirements obtained from 1, 3.1, 5.3 and 5.4; process requirements obtained from 4; obtaining input for the transfer of (design) knowledge into practical application from 6.

Delivering CAD- and FE-models of new components to 2, 3.2, 5 and 6; delivering input (CAD-models) for manufacturing of prototypes to 6.

Discussion of design results as well as optimization goals, strategies and results with partners from all disciplines.

REFERENCES

[Bär-98] Bär, Thomas: Einsatz der Feature-Technologie für die Integration von Berechnungen in die frühen Phasen des Konstruktionsprozesses. Dissertation Universität des Saarlandes, Saarbrücken 1998. Schriftenreihe Produktionstechnik, Band 15.

[BäWe-96] Bär, Thomas; Weber, Christian: Development of an Easy to Use Shape Optimization Tool Based on FEM. 12th International Conference on CAD/CAM, Robotics and Factories of the Future 1996 (CARs & FOF ?96), London/Großbritannien 14.-16.08.1996. Proceedings p. 672-678.

[BäWe-97] Bär, Thomas; Weber, Christian: Support in the Early Design Phase by Working with Intelligent Element Pairs which Simplify the Use of FEM. International Conference on Engineering Design 1997 (ICED 97), Tampere/Finnland 19.-21.08.1997. WDK 25: Proceedings of ICED 97 (ed. by A. Riitahuhta), Vol. 3, p. 231-234. Tampere University of Technology 1997.

[Labi-95] Labisch, Susanna: Untersuchung des Kaltpressens pulverförmiger Stoffe mit Hilfe der Methode der Finiten Elemente unter besonderer Berücksichtigung der Trockenpressung von Sekundärkornmassen. Dissertation Universität des Saarlandes, Saarbrücken 1995. Schriftenreihe Produktionstechnik, Band 11.

[Labi-96] Labisch, Susanna: Simulation des Trockenpressens; Effiziente Verdichtung von Sekundär-kornmassen. Fachtagung ?Simulation mit der Finite-Element-Methode in Feinwerk- und Mikrotechnik", München 12.03.1996. Proceedings, Manuskript Nr. A-10. Institut für Technologie- und Wissenstransfer an der Fachhochschule München e.V., München 1996.

[LaWW-95] Labisch, Susanna; Weber, Christian; Werner, Horst: Investigation of the Stiffness of Individual and Agglomerated Granules by the Finite Element Method. ceramic forum international/Berichte der Deutschen Keramischen Gesellschaft 72 (1995) 9, p. 540-545.

[WeBä-96] Weber, Christian; Bär, Thomas: CASOP - Ein einfach zu handhabendes Gestaltoptimierungswerkzeug, einsetzbar in den frühen Phasen des Konstruktionsprozesses. VDI-Fachtagung ?Informationsverarbeitung in der Konstruktion ?96", München 22.-23.10.1996. VDI-Berichte Nr. 1289, p. 239-253. VDI-Verlag, Düsseldorf 1996.