TY - JOUR A1 - Kneißl, Barbara A1 - Warnck, Moritz A1 - Schneck, Matthias A1 - Schmitt, Matthias A1 - Schlick, Georg T1 - Optimisation of a hydraulic housing for a brake-by-wire system for electrical drives by additive manufacturing JF - Procedia CIRP N2 - Electrical drives in automotive applications require new brake concepts, e.g. to allow recuperation mode. One approach for these are brake-by-wire systems, which are utilized in electrical motorsports. Based on the design freedom of Additive Manufacturing (AM), in particular laser-based powder bed fusion, a function-integrated hydraulic housing for such brake-by-wire systems is developed. The hydraulic housing is a core component of the brake system, as it holds all electric and hydraulic devices and a complex channel system to link the hydraulic devices. Thus, it must fulfill mechanical and hydraulic requirements, as well as a lightweight design in general. Based on a morphological box, which integrates already existing technical approaches and bionic solution principles, two prototypes were developed: One is derived from a current, conventionally manufactured hydraulic housing, and another one, utilizing the AM-capabilities to full extent. Both designs were developed utilizing three CAD tools, in particular Creo Parametric™ for the design itself, Inspire™ for topology optimisation and FEM calculation, and nTopology to generate ripples and lattices, like Voronoi structures. To develop a complex AM-design utilizing different software tools required several manual process steps. Thereby, insufficient software integration was identified as a hindrance to generate complex designs. Finally, both prototypes were manufactured by laser-based powder bed fusion from the aluminum alloy AlSi10Mg. Further optimisation potential exists, but could not be exploited due to insufficient material models for the mechanical design, e.g. fatigue data. Availability of calculation methods for lifetime prediction was identified as another limitation in the design process. UR - https://doi.org/10.1016/j.procir.2022.05.039 KW - e-mobility KW - brake system KW - design optimisation KW - topology optimisation KW - additive manufacturing KW - laser-based powder bed fusion KW - AlSi10Mg Y1 - 2022 UR - https://doi.org/10.1016/j.procir.2022.05.039 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-28831 SN - 2212-8271 VL - 2022 IS - 107 SP - 641 EP - 646 PB - Elsevier CY - Amsterdam ER - TY - JOUR A1 - Schmitt, Matthias A1 - Gottwalt, Albin A1 - Winkler, Jakob A1 - Tobie, Thomas A1 - Schlick, Georg A1 - Stahl, Karsten A1 - Tetzlaff, Ulrich A1 - Schlip, Johannes A1 - Reinhart, Gunther T1 - Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion JF - Metals N2 - The carbon content of steel affects many of its essential properties, e.g., hardness and mechanical strength. In the powder bed fusion process of metals using a laser beam (PBF-LB/M), usually, pre-alloyed metal powder is solidified layer-by-layer using a laser beam to create parts. A reduction of the carbon content in steels is observed during this process. This study examines adding carbon particles to the metal powder and in situ alloying in the PBF-LB/M process as a countermeasure. Suitable carbon particles are selected and their effect on the particle size distribution and homogeneity of the mixtures is analysed. The workability in PBF-LB is then shown. This is followed by an evaluation of the resulting mechanical properties (hardness and mechanical strength) and microstructure in the as-built state and the state after heat treatment. Furthermore, potential use cases like multi-material or functionally graded parts are discussed. UR - https://doi.org/10.3390/met11060896 KW - additive manufacturing KW - PBF-LB/M KW - in situ alloying KW - case-hardening steel KW - 16MnCr5 KW - gears KW - multi-material Y1 - 2021 UR - https://doi.org/10.3390/met11060896 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-10976 SN - 2075-4701 N1 - This article belongs to the Special Issue Advances in Additive Manufacturing of Metals VL - 11 IS - 6 PB - MDPI CY - Basel ER -