PSI - Issue 53
2
Benjamin Möller et al. / Procedia Structural Integrity 53 (2024) 190–202 Author name / Structural Integrity Procedia 00 (2023) 000–000
191
Nomenclature k
slope before the knee point slope after the knee point cycles to failure at the knee point
k * N k P S R F
bending moment amplitude at the knee point
M a,k
survival probability
load ratio
measured notch radius
r notch
T scatter of the fatigue test resulte, derived from the stress amplitudes for P S = 10 % and P S = 90 % a,vM,k von Mises stress amplitude at the knee point notch measured notch opening angle
1. Introduction Additive Manufacturing (AM), on its way to application in structural components, has the advantages in freedom of design, realization of complex geometries or integrating specific functionalities into a component, overcoming some challenges concerning building rate limitations, process-specific effects on AM structures as well as standardization and certification of AM materials and parts, for example. Hence, knowledge from research still required. From this motivation, the research project MULTI-FUN aims to highlight the advantages of additive manufacturing of metallic materials by multi-material and multi-functional design, cf. MULTI-FUN project (2023), Gradinger (2020), Gradinger and Schnall (2020), Gradinger et al. (2020), and Gradinger (2023). 1.1. MULTI-FUN research project The MULTI-FUN project is entitled “Enabling Multi-Functional Performance through Multi-Material Additive Manufacturing” and follows the major project aims related to additively manufactured materials and components: Improvement of the efficiency, quality and reliability of a product by at least 40 % Better use of raw materials and resources with reduced environmental impact and to lower cost by 35 % as demonstrated by life cycle assessment New opportunities and business for SMEs across Europe Following theses general aims, for the demonstration of the research outcome 7 demonstrators – 6 physical parts and one process development – were set up. For the majority of demonstrators, wire arc additive manufacturing (WAAM) was chosen as AM manufacturing process. Investigated materials show a variety, focusing on metals. With respect to quality approval and reliability, assessment the structural durability. This publication focuses on the design and fatigue assessment of the demonstrator “motorcycle handlebar” (demo 2). 1.2. Design of a multi-functional motorcycle handlebar Within the design of the motorcycle handlebar (demo 2), a focus was set on functional integration and multi material-design in combination with an aerodynamical shape (droplet shape of the handlebar section), Fig. 1. The functional integration includes integration of copper conductors and ceramic isolators (electric connection) and hydraulic lanes (brake, clutch). Some aspects on the integration of electrical conductors into light metal has been shown by Hohm and Gradinger (2022). While hydraulic lanes will be fed through a channel after the WAAM of a hollow structure, the conductors are realized by adding copper and Al 2 O 3 -ceramics material to the aluminum base
Made with FlippingBook Ebook Creator