Best practice: Forecasts for component properties Additive manufacturing processes for production in the automotive industry
© DF.FotografieThe challenge: The automotive industry sees great potential in additive manufacturing processes, particularly in melt-based processes such as fused deposition modelling (FDM). These offer advantages in terms of production speed and material diversity. However, a major hurdle is that the quality of the components is currently not comparable to that of injection-moulded series products. There is also a lack of models that allow the mechanical properties of additively manufactured components to be predicted. The aim of the project was to identify relevant process and material parameters and to understand their influence on the component properties in order to better integrate melt-based processes into existing production processes.
Identification of relevant process parameters
Investigation of the interactions between machine parameters and component quality.
Evaluation of the process parameters with regard to their significance for the properties of the manufactured components.
Procedure:
Critical parameters such as temperature profiles, layer height and pressure distribution were determined as part of detailed process analyses. Their effects on the material structure and component strength were systematically investigated and documented in tests.
Material qualification
Pre-selection of suitable plastics based on specific requirements.
Characterisation of material properties such as flow behavior, solidification processes and processing suitability.
Procedure
Laboratory analyses and simulations were used to evaluate plastics that can withstand both mechanical loads and thermal influences. A particular focus was placed on the suitability for processing with FDM methods.
Sensor integration
Development of sensor systems for inline measurement of process parameters.
Active control of parameters to minimize fluctuations during the production process.
Procedure:
Specialized sensors were installed to measure temperature and pressure curves during production. The data obtained was used to monitor and adjust processes in real time.
Development and optimisation of representative components.
Production and characterization of demonstrators with regard to mechanical and morphological properties.
Procedure
Prototypes were additively manufactured and extensively tested. Special characteristics such as component strength, surface structure and dimensional accuracy were analysed. The knowledge gained was directly incorporated into the optimisation of the processes.
Development of a model system
Creation of models that predict the properties of the components based on the process parameters.
Validation of the models with the manufactured demonstrator components.
Procedure:
Based on the experimental data, a model was developed that can predict the properties of additively manufactured components with high precision. Validation was carried out by comparison with real measurement results.
Results:
The project provided comprehensive findings on the interactions between material, process and machine parameters in FDM processes. The models developed make it possible for the first time to reliably predict component properties. By using optimized processes and materials, it was possible to produce demonstrator components whose quality is significantly closer to that of series products.
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