Innovation

Durch die Forschung des DMRC konnten einige Innovationen entwickelt werden. Diese Innovationen treten in verschiedenen Forschungsfeldern auf und werden hier näher dargestellt.
Additive Manufacturing of electric machines: permanent magnet synchronous machine rotors

For applications in electrical machines, AM
provides exciting new possibilities. The process-
specific freedom of design enables
themeconomical production of geometrically
complex components, since the component
complexity has only a minor influence on the
production costs.
Additive Marking - Efficient marking of digital product data for AM processes

Markings can be understood as a kind of individualization of parts. As individualization does not increase production costs when using AM the only effort results from the integration of markings in the digital product data.

 

 
Build-chamber preheating system for SLM

Additive manufacturing (AM) of metal components attracts substantial attention. By employing AM, highly complex parts can be generated with additional functionalities such as contour near cooling, sensor systems, or permeable structures. With regard to selective laser melting filigree parts can be generated in a near net shape fashion. However, alloys processible via SLM are limited. Improved SLM manufacturing conditions can be achieved either by material adjustments consistent powder heating up to 800 °C.
Direct damping of an armature plate used in a spring-loaded brake

In drive systems, spring-loaded brakes are commonly used to slow down, stop and lock the drive system. They are located at the B-side of electric motors. While braking, the armature plate is pressed against the rotating friction lining by spring elements. To release the brake, an electro magnet rescinds the spring forces. The fast movement of the armature plate leads to strong impacts with the friction lining and the housing of the electric motor. This results in a vibration of the brake-system and the emission of perceivable noise.
Design and drive technology in an AM-optimized modular drive

The focus of the scientific work of the Chair of Design and Drive Technology (KAt) are electromechanical drive technology and design aspects in additive manufacturing processes. In the research project “KAtAMaran” (“Design and drive technology in an AM-optimized modular drive”), a modular multi-motor drive system (short: MMDS) is being developed as a research platform that exhibits the design freedom of additive manufacturing and the advantages of function integration.
Exploiting the advantages of additive manufacturing processes in medical technology

Additive manufacturing processes are playing an increasingly important role in the field of medical technology. They make it possible to meet the demand and need for patient-specific products. The high design freedom of additive manufacturing processes in combination with CAE methods is used to provide approaches to solve the existing stiffness problem in hip endoprosthetics. Using stress adapted geometries and the finite element method, stiffness adapted variants of a short shaft hip endoprosthesis are developed in an iterative process.
Fused Deposition Modeling with metal powder filled filaments

The processing of metal powder filled polymer filaments in Fused Deposition Modeling (FDM) presents a comparatively new technology for the production of metal components. This technology enables powder-free handling of the base material and processing on low-cost FDM equipment. The aim of the research in cooperation with DMRC industrial consortium is to achieve a better understanding of the technology throughout the entire process chain.
Lightweight design of SLM hydraulic clamping devices

The project is about a technical and economic
study for the feasibility of a base body for a
hydraulic clamping fixture by using the advan-
tages of the SLM process. So far the fixture is
made in several machining steps out of one solid
piece of steel.

 

 
Lightweight PMSM Rotor Shaft

The aim of the project was the identification of benefits of Additive Manufacturing (AM) in electric engineering and especially the implementation of this benefits in a Permanent Magnet Synchronous Motor (PMSM).

 

 
Low Temp Laser Sintering

The laser-sintering process has, beside all the advantages like a high productivity and a great design freedom, significant disadvantages with the low material variety and material ageing. A major proportion of all LS components are still made of PA12 and PA11. High performance materials e.g. PA6, PPS, PEKK, etc. are appearing increasingly on the market but they cannot be processed on standard LS systems due to the higher processing temperature.
Modelling of temperatures and heat flow within laser sintered part cake

Temperature effects in the polymer laser sintering process are an important aspect regarding the process reproducibility and part quality. Depending on the job layout and position within the part cake, individual temperature histories occur during the process.

 
Optimization of Material properties of selective Laser-Melted Aluminium Alloy 7075

Experience from conventional manufacturing shows a good performance of the high-strength aluminum alloy EN AW 7075 which leads to frequent use in automotive and aerospace sector. Scientific investigations on the processability of this alloy in the SLM process shows that prepared samples have anisotropic behavior due to process-induced hot cracks.
Plastic freeforming of liquid-tight microfluidic components

A design adjustment of the inner structure minimizes the floating overhangs in the range of the flow channels. Due to this adjustment, the use of any kind of support material can be avoided. In this way it can be ensured that no residues of water soluble or non-biocompatible material remain in the system.


 
Surface roughness optimization by simulation & part orientation

The layered structure of Additive Manufacturing processes results in a stair-stepping effect of the surface topographies. In general, the impact of this effect strongly depends on the build angle of a surface whereas the overall surface roughness is caused by the resolution of the specific AM process. The aim of this work is the prediction of surface quality in dependence of the part building orientation.
Polymer Powder Spread Process Monitoring System

Machine and part qualification are always based on the information gathered. For a proper qualification and for confidence gaining in the LS technology the process itself should be observed and monitored as precisely as possible. Within this DMRC project a high-resolution images-based powder spread monitoring system for the laser sintering process has been developed.

 
Weld seam strenght qualification of new FDM materials

A component is created in the Fused Deposition Modeling (FDM) process by depositing a polymer strand layer by layer. Due to thermal fusion, the deposited material bonds with the layer below. This leads to the characteristic welded seams of the FDM process. Therefore, an essential part of the qualification of new materials for the FDM process is the evaluation of the processing suitability by means of the weld seam quality.