带巡回集成的新型激光烧结机的系统开发与可持续性评估

Machines Pub Date : 2024-05-14 DOI:10.3390/machines12050336
Michael Baranowski, Johannes Scholz, F. Kößler, Jürgen Fleischer
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引用次数: 0

摘要

在增材制造工艺中加入连续碳纤维增强聚合物(CCFRP)部件,是制造坚固轻质部件的一大进步,尤其适用于航空航天、工程和各种工业领域。然而,目前用于 CCFRP 部件的增材制造方法存在明显的局限性。依赖树脂和挤压的技术需要大量昂贵的后处理程序来消除支撑结构,从而限制了设计的多功能性,并使小规模生产变得更加复杂。与此相反,激光烧结(LS)成为一种很有前途的工业应用途径。它无需支撑结构,就能高效、经济地制造弹性部件。然而,就目前的研究和技术能力而言,还没有一台 LS 设备能将连续纤维加固的优势与 LS 工艺的固有优势融为一体。本文介绍了根据 VDI 2221 标准系统开发新型 LS 设备的过程,该设备可自动集成连续纤维,同时保持 LS 工艺的优势。本文还介绍了该机器的物理原型。此外,本研究还提出了一种在产品设计中整合工艺成本和产品碳足迹的方法。为此,开发了一个机器状态模型,并根据该模型分析了零件的成本和产品碳足迹。通过生产 CCFRP 部件,展示了未来轻质产品的巨大潜力。
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Systematic Development of a Novel Laser-Sintering Machine with Roving Integration and Sustainability Evaluation
Incorporating continuous carbon fibre-reinforced polymer (CCFRP) parts within additive manufacturing processes presents a significant advancement in the fabrication of robust lightweight parts, particularly relevant to aerospace, engineering, and various industrial sectors. Nonetheless, prevailing additive manufacturing methodologies for CCFRP parts exhibit notable limitations. Techniques reliant on resin and extrusion entail extensive and costly post-processing procedures to eliminate support structures, constraining design versatility and complicating small-scale production endeavours. In contrast, laser sintering (LS) emerges as a promising avenue for industrial application. It facilitates the efficient and cost-effective manufacturing of resilient parts without needing support structures. However, the current state of research and technological capabilities has yet to yield an LS machine that integrates the benefits of continuous fibre reinforcement with the inherent advantages of the LS process. This paper describes the systematic development process according to VDI 2221 of a new type of LS machine with automated continuous fibre integration while keeping the advantages of the LS process. The resulting physical prototype of the machine is also presented. Furthermore, this study presents an approach to integrate the cost and Product Carbon Footprint of the process in the product design. For this purpose, a machine state model was developed, and the costs and Product Carbon footprint of a part were analysed based on the model. The promising potential for future lightweight products is demonstrated through the production of CCFRP parts.
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