Modular rapid design of multi-material lightweight truss structures – A novel approach
Rathert T, Witzgall C, Wartzack S (2018)
Publication Language: English
Publication Type: Conference contribution, Conference Contribution
Publication year: 2018
Pages Range: 21-23
Conference Proceedings Title: Book of Abstracts. Symposium Lightweight Design in Product Development, Zurich
Event location: Zürich
Abstract
The specification of an ideal lightweight design with minimal weight and maximum utilization of the material is often restricted by economic factors. Taking this into account, only an optimized lightweight design can be realized. When utilizing modern composite materials, the design and manufacturing methods are poorly standardized and their implementation usually causes high costs in design and production. Besides that the composite suitability of framework structures – which could be standardized – is only given for uniaxial loaded sections, whereas the connector regions are subject to a (at least) biaxial stress state that is very unfavorable for composite materials. As a consequence it is often advisable to use a multi-material design – also known as hybrid design. The best properties of different materials are combined here, while keeping the economic impact as low as possible. Each individual element of the hybrid structure offers a basic local solution, but in addition they can achieve optimization in a combined state. The main objective of this contribution is to show how to simply use the right material in the right place, thus allowing to optimally exploiting their beneficial lightweight properties and keeping the costs as low as possible. Therefore a methodology is presented, which allows the dimensioning and optimization of multi-material lightweight design systems inside a restricted design space by using modular and rapid building blocks. This enables the product developer to design an optimal framework topology by using a discrete optimization approach and afterwards dimension anisotropic composite tubes for the sections of uniaxial stresses and isotropic connectors to join them. The calculated information is then transferred to the CAD‑System to directly create the product’s embodiment design by using standardized composite profiles and aluminum connectors. Finally using the demonstrator of a motorcycle frame, the method will be evaluated and discussed.
Authors with CRIS profile
Thomas Rathert
Chair of Engineering Design
Christian Witzgall
Chair of Engineering Design
Sandro Wartzack
Chair of Engineering Design
Related research project(s)
How to cite
APA:
Rathert, T., Witzgall, C., & Wartzack, S. (2018). Modular rapid design of multi-material lightweight truss structures – A novel approach. In Ermanni, Paolo; Meboldt, Mirko; Wartzack, Sandro; Krause, Dieter; Zogg, Markus (Eds.), Book of Abstracts. Symposium Lightweight Design in Product Development, Zurich (pp. 21-23). Zürich, CH.
MLA:
Rathert, Thomas, Christian Witzgall, and Sandro Wartzack. "Modular rapid design of multi-material lightweight truss structures – A novel approach." Proceedings of the 1st Symposium for Lightweight Design and Product Development, Zürich Ed. Ermanni, Paolo; Meboldt, Mirko; Wartzack, Sandro; Krause, Dieter; Zogg, Markus, 2018. 21-23.
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