Fusion 360 Istanbul IT Makina Fakltesi Tayfun Sle // April 11th - - PowerPoint PPT Presentation

3D Printing introduction + Topology Optimization with Fusion 360

Istanbul – ITÜ Makina Fakültesi

Tayfun Süle // April 11th

Tayfun un Süle le

Team leader ALM / 3D Printing

B.Eng. Aircraft Engineer M.Sc. Composites Since 2011 working for the Heinkel Group Since 2014 responsible for ALM activities

…by www.heinkel-group.com

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Who are we?

…by www.heinkel-group.com

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Headquarter in

Hamburg,

Germany

family owned since

1974

• ver

120

employees from

20 nations

Who are we?

…by www.heinkel-group.com

4 Strategy & Projects HR Services Over 100 experts in all industries

What t are we doing? ng?

…by www.heinkel-group.com

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Facts ts

Established: 2013 Geschultes Personal: 17 Industries: Aerospace Automotive Mechanical Eng. Steel Fashion Food

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Teamleader

Workshops / Construction

Engineering

Topology Optimization / Construction

Testing

Static & environmental Testing

Your exper erts s for addit itiv ive e manufac ufactur turing ng

…by www.heinkel-group.com

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Consulting

• Part Screening
• Serial

development

• Workshops

Development

• Design /

Construction

• Reverse

Engineering

• Optimization

Manufacturing

• Prototypes
• Series

Testing

• Static Testing
• Dynamic Testing

What t is 3D Printing? ting?

• Laying down thin layers of

material

• Creating of objects from 3D

CAD Model

…by www.heinkel-group.com

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https://de.wikipedia.org/wiki/3D-Druck

FDM DM – Fused sed Depo posit sit Moulding lding

• Melting Material thru hot nozzle
• Material just on locations, where

it is needed

• Mainly used for Plastics

…by www.heinkel-group.com

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SLM – Select ectiv ive e Laser r Meltin ing

• Material melted with a laser
• Mainly used for Metals

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Materi rial als

• All weldable metals (Steel,

Aluminium, Titanium, Gold, …)

• Plastics (ABS, PLA, PVA, PET, …)
• Ceramics
• Organics
• Food, Glass, …

…by www.heinkel-group.com

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http://www.lboro.ac.uk/microsites/enterprise/e2hs/ http://www.insidemetaladditivemanufacturing.com

Histo tory ry

• Developed in 1983 from Chuck

Hall

• Main Reason: fast Prototyping
• First Patents in 1986

…by www.heinkel-group.com

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https://www.epo.org/learning-events/european-inventor/finalists/2014/hull_de.html

For who is it useful? ful?

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Industrial use Home use

Indu dustr stria ial l Use

• Manufacturing of small batches
• Weight loss for complex parts
• Faster manufacturing for complex

parts

• Integration of new functions
• Simplifying complex assemblies
• Designs which are not possible

with conventional processes

…by www.heinkel-group.com

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http://www.airbusgroup.com/int/en/story-overview/Pioneering-bionic-3D-printing.html

Disadv sadvantages antages of AM

• Slow!
• Automatization
• Quality
• High Invest
• Materials
• Know How
• Certification
• …

Why?

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Adv dvantages ntages of AM

• Data for manufacturing can be

directly used from CAD Systems (Autodesk, CATIA, …)

• Small batches staring from lotsize 1
• Reducing of development time
• No Tools are needed (Moulds etc)
• Geometrical Freedom
• Weight
• Function
• Complex structures
• Substitution of parts

…by www.heinkel-group.com

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EADS Case Study – 3D Printing

Geometr tric ical al Freedo edom

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Complexity Costs Conventionally Manufacturing Additive Manufacturing

Complexity for free ->

Findi nding ng the right t Brack ckets ts and Assembli semblies

• Total of 5 Parts (2 Milled, 3 Sheet

Metal)

• Connecting Devices (17)
• Total Weight of 239 g

…by www.heinkel-group.com

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Topo pology logy optimizatio imization

1. Creation of Design space 2. Mark areas which can´t be changed

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Result ult of Topolog

• logy

Optim imiza ization tion

• 3. Understanding the results
• 4. Creation of CAD Model
• 5. Analyze

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Final al Part

Final weight: 53 g Parts: 1 Connecting Devices: 9

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Examp mple e

Wardrobe Hook Attachments: 2 Force: 100 N Weight: 223 g Next Step: Analyse current stresses – F360

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Examp mple e

Wardrobe Hook Max Stress: 24.3 Mpa Max Deformation: 0.32 mm Next Step: Creation of Design Space – F360

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Examp mple e

Wardrobe Hook Creation of Design Space

• Extend Space wherever it is

possible Next Step: Creation of Boundary Conditions – F360

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Examp mple e

Wardrobe Hook Creation of Boundary Conditions Next Step: Creation of Loads– F360

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Examp mple e

Wardrobe Hook Creation of Loads Next Step: Choose of Shape Optimization Goal – F360

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Examp mple e

Wardrobe Hook Shape Optimization Goal Next Step: TopOpt Example

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Topo pology logy Optim imization ation App pp

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Optim imiza ization tion Task

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Result ult

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Examp mple e

Wardrobe Hook Understand Results Next Step: Creation CAD Model

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Examp mple e

Wardrobe Hook Creation of 3D Model Attachments: 1 Force: 100 N Weight: 77 g Next Step: Analyse new Design

…by www.heinkel-group.com

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Examp mple e

Wardrobe Hook Analyse of new Design Max Stress: 82.9 Mpa Max Deformation: 0.10 mm Next Step: Compare Models

…by www.heinkel-group.com

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Examp mple

Rendering Weight:

• 65 %

Connecting Devices:

• 50 %

Max Stresses: + 50 Mpa

(Not critical)

Deformation:

• 68 %

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Examp mple e Render derin ing

Tutorial in Fusion 360

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BERATUNG | ENTWICKLUNG | DRUCK www.bionic-studio.com

Thank you for your Attention

Tayfun Süle

Teamleader ALM ts@bionic-studio.com