Proceedings of the munich symposium on lightweight design 2020: tagungsband zum münchner leichtbauseminar 2020. english and german

Every year, the Technical University of Munich, the Bundeswehr University, and the University of Applied Sciences in Munich invite researchers and practitioners to join the Munich Symposium on Lightweight Design. Experts from industry and academia discuss design tools, applications, and new developments. Topics include, e.g., composite structures, SHM, microstructures, material modelling, design for additive manufacturing, numerical optimization and in particular topology optimization in aerospace, automotive and other industries. The talks are summarized in short articles and presented in this volume. The Editors Simon Pfingstl (*1994) is a research associate at the Laboratory for Product Development and Lightweight Design at the Technical University of Munich (TUM). His research is about statistical methods and machine learning techniques, such as Gaussian processes, and their application to prognostic health monitoring of aircraft structures. Before he became a research associate, he studied automotive engineering (B.Sc.) and computational engineering (M.Sc.) at the University of Applied Sciences Munich with a focus on structural mechanics and optimization. Alexander Horoschenkoff (*1960) studied mechanical engineering at TUM and received his PhD from the mechanical engineering department. He started his career at the research center of Messerschmitt-Bölkow-Blohm (MBB) in Ottobrunn. Within the research core team of the DaimlerChrysler AG he was responsible for the mechanical technology field. Since 2001 he has been a professor at the Munich University of Applied Sciences, Department of Mechanical Engineering, Automotive and Aeronautics Engineering and head of the CC "Smart Composites". Philipp Höfer (*1979) is a full professor at the Institute of Lightweight Engineering within the Department of Aerospace Engineering at the Universität der Bundeswehr München. After obtaining his PhD in the field of material modelling and continuum mechanics, he has gained extensive experience in the development of aircraft structures at Airbus over many years. His research interests include the conceptual, functional and structural design of lightweight structures and the investigation of their static and dynamic characteristics by analysis and test. Markus Zimmermann's (*1976) research is about the design and optimization of complex mechanical systems, such as automobiles or robots. Before he became a professor at TUM, he spent 12 years at BMW designing vehicles for crash and vehicle dynamics. His academic training is in Mechanical Engineering with degrees from the Technical University of Berlin (Diplom), the University of Michigan (M.S.E.) and MIT (Ph.D.) Preface Organization Contents 1 Design of a motorcycle triple clamp optimised for stiffness and damping 1 Introduction 2 Theoretical background 2.1 Hand-arm vibrations 2.2 Measures to reduce hand-arm vibrations on motorcycles 2.3 Use of laser beam melted particle dampers 3 Design of a motorcycle triple clamp 3.1 Methological approach 3.2 Determining the load conditions on the motorcycle stem 3.3 Parameter study of the triple clamp 3.4 Topology optimisation 3.5 Insertion of cavities for the integration of particle damping 3.6 Proof of static strength 4 Discussion 5 Conclusion 6 References 2 Fully Automated Subdivision Surface Parametrization for Topology Optimized Structures and Frame Structures using Euclidean Distance Transformation and Homotopic Thinning Abstract 1 Introduction 2 State of the Art 3 Parametrization 4 Parametrization of Topology Optimization Results 4.1 Fully Automated Skin Subdivision Surface Parametrization 4.2 Shape Adjustment on Skin Subdivision Surfaces 5 Conclusion 6 Acknowledgment References 3 A Concept Towards Automated Reconstruction of Topology Optimized Structures Using Medial Axis Skeletons 1 Redesign of topology optimized structures 2 An approach towards a more automated reconstruction of topology optimization results 2.1 Analysis 2.2 Synthesis 3 Redesign of a turbine engine bracket with a more automated approach to reconstruction of topology optimization results 4 Summary and Outlook 5 Acknowledgements References 4 Design and Optimization of Ultra-Stable Fine-Pointing Structures for the CHIME Instrument 1 Introduction 2 Design Trade-Offs 2.1 Honeycomb Panel Design 2.2 Monolithic Metal Design 2.3 CFRP Frame Design 3 Spectrometer Mounting Structure Design and Optimization 4 CFRP Frame Hardware Test 5 Conclusions and Outlook References 5 Lightweight engineering design of nonlinear dynamic systems with gradient-based structural design optimization 1 The Virtuous Circle of Lightweight Engineering Design 2 Sensitivity analysis of nonlinear dynamic systems 3 Structural dynamics 3.1 Governing equation 3.1.1 Primary analysis 3.1.2 Sensitivity analysis 3.2 Time integration 3.2.1 Primary analysis 3.2.2 Sensitivity analysis 3.3 Nonlinear solver 3.3.1 Primary analysis 3.3.2 Sensitivity analysis 4 Rigid multibody dynamics 4.1 Governing equation 4.1.1 Primary analysis 4.1.2 Sensitivity analysis 4.2 Time integration 4.3 Nonlinear solver 4.3.1 Primary analysis 4.3.2 Sensitivity analysis 5 Numerical example – Optimal design of a hydropower intake rack cleaning mechanism 6 Conclusion Acknowledgments References 6 Hard- and Software fusion for process monitoring during machining of fiber reinforced materials 1 Introduction 2 Hardware fusion 3 Software fusion 4 Conclusions References 7 Additive manufactured break-out cores for composite production: A case study with motorcycle parts 1 Introduction 2 Additive manufactured break-out cores 3 Design of breaking lines 4 Case study 4.1 Flow intake 4.2 Tank structure 5 Discussion 6 Summary and outlook References 8 Neue Bauweisen von Wasserstoffdruckbehältern für die Integration in zukünftige Fahrzeugarchitekturen 1 Motivation und Stand der Technik 1.1 Ökologischer und wirtschaftlicher Hintergrund der Untersuchungen 1.2 Fahrzeugarchitekturen für zukünftige emissionsfreie Antriebsvarianten 1.3 Geometrische Anpassung der Druckbehälterform als Lösung 1.4 Wasserstoffspeicher in aktuellen Brennstoffzellenfahrzeugen 2 Zylindrische Druckbehälter 2.1 Konzeptvarianten 2.2 Fertigungstechnologie und Permeation als zentrale Herausforderungen 2.3 Abschätzung des Einsatzpotenzials für zukünftige Fahrzeugarchitekturen 3 Quaderförmige Druckbehälter mit Zugstreben 3.1 Konzeptvarianten 3.2 Außengeometrie des Behälters und Grobauslegung der Zugstreben 3.3 Fertigungsverfahren 3.4 Abschätzung des Einsatzpotenzials für zukünftige Fahrzeugarchitekturen 4 Schlussfolgerung Literatur 9 Bauraumoptimierter Wasserstoff Tank mit innerer Zugverstrebung 1 Problemstellung, Bauweise und Dichtigkeit 2 Fertigungskonzept 3 Zusammenfassung Literaturverzeichnis 10 Innovative design and manufacturing techniques for fiber reinforced plastic components 1 Introduction 2 Trace (Tsai’s modulus1) on engineering constants 3 Universal and Master Ply Constants and Laminate Factors 4 Unit circle criterion 5 Double-double architecture for sub-laminates 5.1 Field equation for stiffness 5.2 Homogenization 5.3 Quad-axial replacements 5.4 Optimization by Lamsearch 5.5 Manufacturing of double and double-double fabrics and tapes 6 Skin-grid structures References 11 Application of Tsai’s Theory for the Laminate Optimization of an Aerospace Wing Box 1 Introduction 2 Optimization of a Wing Box 2.1 Finite Element Model 2.2 Laminate Optimization with EA and ARSM 2.3 Laminate Optimization with Laminate Search 2.4 Thickness Scaling 3 Discussion of the Wing Box Optimization 3.1 Material Selection 3.2 Comparison with Aluminum 3.3 Laminate Homogenization Conclusion Declaration of Competing Interest References Author Index Every year, the Technical University of Munich, the Bundeswehr University, and the University of Applied Sciences in Munich invite researchers and practitioners to join the Munich Symposium on Lightweight Design. Experts from industry and academia discuss design tools, applications, and new developments. Topics include, e.g., composite structures, SHM, microstructures, material modelling, design for additive manufacturing, numerical optimization and in particular topology optimization in aerospace, automotive and other industries. The talks are summarized in short articles and presented in this volume. The Editors Simon Pfingstl (*1994) is a research associate at the Laboratory for Product Development and Lightweight Design at the Technical University of Munich (TUM). His research is about statistical methods and machine learning techniques, such as Gaussian processes, and their application to prognostic health monitoring of aircraft structures. Before he became a research associate, he studied automotive engineering (B.Sc.) and computational engineering (M.Sc.) at the University of Applied Sciences Munich with a focus on structural mechanics and optimization. Alexander Horoschenkoff (*1960) studied mechanical engineering at TUM and received his PhD from the mechanical engineering department. He started his career at the research center of Messerschmitt-Bölkow-Blohm (MBB) in Ottobrunn. Within the research core team of the DaimlerChrysler AG he was responsible for the mechanical technology field. Since 2001 he has been a professor at the Munich University of Applied Sciences, Department of Mechanical Engineering, Automotive and Aeronautics Engineering and head of the CC "Smart Composites". Philipp Höfer (*1979) is a full professor at the Institute of Lightweight Engineering within the Department of Aerospace Engineering at the Universität der Bundeswehr München. After obtaining his PhD in the field of material modelling and continuum mechanics, he has gained extensive experience in the development of aircraft structures at Airbus over many years. His research interests include the conceptual, functional and structural design of lightweight structures and the investigation of their static and dynamic characteristics by analysis and test. Markus Zimmermann's (*1976) research is about the design and optimization of complex mechanical systems, such as automobiles or robots. Before he became a professor at TUM, he spent 12 years at BMW designing vehicles for crash and vehicle dynamics. His academic training is in Mechanical Engineering with degrees from the Technical University of Berlin (Diplom), the University of Michigan (M.S.E.) and MIT (Ph.D.)