Validierung von prozessgerecht strukturoptimierten Bauteilentwürfen mittels integrierter FEM-Realgeometrieanalyse

Year: 2015
Editor: Dieter Krause, Kristin Paetzold, Sandro Wartzack
Author: Stefan Hautsch, Sebastian Katona, Tobias Sprügel, Michael Koch, Frank Rieg, Sandro Wartzack
Series: DfX
Institution: Universität Bayreuth
Section: Methodisches Vorgehen zur Validierung und Verifikation
Page(s): 181-192
ISBN: 978-3-941492-93-6


Structural optimization as a tool of the virtual product development process
(PDP) provides broad possibilities to scoop lightweight design and improvement potentialities
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 procedure, 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 optimization tools and a knowledge database, illustrated exemplarily by the
forming process. 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 relevance to
the part's performance and the design can be safeguarded.

Keywords: validation, finite element analysis, structural optimization, 3D scan

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