Validierung von prozessgerecht strukturoptimierten Bauteilentwürfen mittels integrierter FEM-Realgeometrieanalyse

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Hautsch, Stefan ; Katona, Sebastian ; Sprügel, Tobias ; Koch, Michael ; Rieg, Frank ; Wartzack, Sandro:
Validierung von prozessgerecht strukturoptimierten Bauteilentwürfen mittels integrierter FEM-Realgeometrieanalyse.
In: Krause, Dieter ; Paetzold, Kristin ; Wartzack, Sandro , Institut für Technische Produktentwicklung (ITPE) Universität der Bundeswehr München (ed.): Design for X : Beiträge zum 26. DfX-Symposium, Oktober 2015. - Hamburg : TuTech Verlag , 2015 . - pp. 181-192
ISBN 978-3-941492-93-6

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Structural optimization as a tool of the virtual product development process (PDP) provides broad possibilities to scoop lightweight design and improvement poten-tialities when developing new products. To promote the further dissemination of structural optimization, the focus of the developments lies on a process-ready structural optimization, which does not only aim at design, safeguarding and later alteration through process restrictions , but at a straightforward generation of process- and production-ready parts by using computer-aided optimization tools. This efficient approach in product development helps to reduce iterations in the PDP, but also brings along the need for a validation of the newly created proce-dure, because manufacturing processes like forming often cause deviations in the physical part which were not regarded in the dimensioning of the desired part. Hence the established simulation of the desired component design (based on 3D CAD data) should be supplemented with a simulation of the physical part‘s geometry (based on the 3D scan of a prototype). The overvalue of the current development is a efficiency increase of the product development process through reduction of unneccessary iteration loops and effective generation of process-, production- and utilization-ready part designs with the aid of structural optimizati-on tools and a knowledge database, illustrated exemplarily by the forming pro-cess. The finite element (FE) analysis of the desired geometry is joined by a validation of the adapted product development process by geometry analysis and FE-simulation of the physical geometry provided by a 3D scanner. Consequently, the deviations made by the manufacturing process can be analyzed for their rele-vance to the part's performance and the design can be safeguarded.