Abstract
Purpose Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production parameters as well as experimental validation. Design/methodology/approach Multi-curved, sandwich structure-based demonstrators were designed, simulated and experimentally tested with boundary conformal lattice cells. The demonstrator’s non-periodic lattice cells were simplified by forward homogenization processes. To represent the stiffness of the top and bottom face sheet, constant isotropic and mapped transversely isotropic simulation approaches were compared. The dimensional accuracy of lattice cells and demonstrators were measured with a gauge caliper and a three-dimensional scanning system. The optimized process parameters for lattice structures were transferred onto a large volume laser sintering system. The stiffness of each finite element analysis was verified by an experimental test setup including a digital image correlation system. Findings The stiffness prediction of the mapped was superior to the constant approach and underestimated the test results with −6.5%. Using a full scale fairing the applicability of the development process was successfully demonstrated. Originality/value The design approach elaborated in this research covers aspects from efficient geometry generation over structural simulation to experimental testing of produced parts. This methodology is not only relevant in the context of motor sports but is transferrable for all additively manufactured large scale components featuring a complex lattice sub-structure and is, therefore, relevant across industries.
Highlights
IntroductionLattice structures deliver a high bending stiffness to weight ratio and, are suited well for lightweight structures (Gibson and Ashby, 1999)
This design approach demonstrates that different types of lattice structures can be combined with each other and reinforcement surfaces can be added to the core
The layout of this study successfully demonstrated the possibility to predict the stiffness of non-periodic PA12 sandwich structures in margin of error of À7% or À9% depending on deflection position
Summary
Lattice structures deliver a high bending stiffness to weight ratio and, are suited well for lightweight structures (Gibson and Ashby, 1999). Rosen (2007) introduced the potential of the design method for additive manufacturing using a slightly curved plate filled with a boundary conformal lattice structure as demonstrator. The current issue and full text archive of this journal is available on Emerald Insight at: https://www.emerald.com/insight/1355-2546.htm. The full terms of this licence may be seen at http://creativecommons.org/licences/by/4.0/legalcode
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