Workshop IA-HEV Task 17 Overview of Lightweight Design ......ETH Zurich Dept. Mechanical & Process...
Transcript of Workshop IA-HEV Task 17 Overview of Lightweight Design ......ETH Zurich Dept. Mechanical & Process...
Workshop IA-HEV Task 17
Prof. Dr. Arne Wahlen, 9th October 2014
Overview of Lightweight
Design Research Activities at
Swiss Universities
© Audi
Contents
Introduction
Overview Swiss Technical Universities
Research Topics
M.Sc. Materials Science, ETH Zurich
Dr. sc. techn., ETH Zurich
Light Metals Technologies, A-Ranshofen
Alcan Research Center, Neuhausen
Alu Menziken Aerospace, Menziken
Since February 2009: University of
Applied Sciences Northwestern
Switzerland (FHNW)
E-Mail: [email protected]
Arne Wahlen
Lightweight design is a design philosophy with the aim of
maximum weight reduction.
The reasons for lightweight design are manifold, e.g.
saving of raw materials, reducing costs and CO2 emissions.
Lightweight materials are aluminium alloys, magnesium
alloys, high-strength steels, titanium alloys and fiber
composites.
Overview of Lightweight Design Research
Activities at Swiss Universities
Case Study
Materials Selection for Table Legs
Boundary Conditions
Table with a given table board (length and width)
Table height and weight are fix
Table legs must not bend
Specifications
Table legs must be circular,
light and as slender as
possible
Question
Which material do you choose?
5
Requirements
1) as light as possible
2) as slender as possible
Euler Buckling Modes
6
I: Second moment of inertia
For rods: I=pr4/4
Case Study
Materials Selection for Table Legs
7
Criterion
«Lightweight»
Criterion «Slenderness»
Selection
Case Study
Materials Selection for Table Legs
Table
Material Density Young’s Mod. Material Index
r [g/cm3] E [GPa] M = r/√E
Oak 0.67 13 0.19
Fir 0.58 7.2 0.22
Steel 7.87 210 0.54
Aluminium 2.71 70 0.32
Magnesium 1.74 42 0.27
Titanium 4.51 105 0.44
Composite 1.50 140 0.13
8
Case Study
Materials Selection for Table Legs
Contents
Introduction
Overview Swiss Technical Universities
Research Topics
Swiss Technical Universities
Swiss Federal Institute of Technology Zurich (ETHZ)
Budget: 1200 Mio. €/year, 18000 students
Ranking: QS 3rd in Eng.
Swiss Federal Institute of Technology Lausanne (EPFL)
Budget: 660 Mio. €/year, 9000 students
Ranking: QS 10th in Eng.
Swiss Universities of Applied Sciences
Diploma in Bachelor of Science
(Technical Universities: Master of Science)
New Master Diploma Degree:
Funded by cantons
(TU: Swiss government)
R&D
Research Focus
Federal Technical
Universitiestop-down
Universities of
Applied Sciences bottom-up
Industry
different time scales
of projects
“Education at ETH Zürich
generally focuses more
on theoretical aspects
than application.”
Source: Wikipedia
Contents
Introduction
Swiss Technical Universities
Research Topics
Research Topics
Swiss Technical Universities
ETH Zurich
Dept. Mechanical & Process Engineering
Biggest Department of ETH Zurich with 30 professors.
ETH Zurich
Dept. Mechanical & Process Engineering
The Institute of Design, Materials and Fabrication (IDMF) focuses
on Engineering Design as a fundamental discipline within Mechanical
Engineering, which includes the development and integration of novel
material systems, design methodology, methods and tools that lead to innovative
technical solutions and their integration with novel fabrication processes. IDMF
will develop new synergies in research and industrial collaboration as well as in
the Engineering Design education.
The Laboratory of Composite Materials and Adaptive Structures develops
material systems with adjustable mechanical properties to realize higher quality
lightweight structures with integrated functionalities. Examples can be found in
the area of deformable aerodynamic structures and active vibration damping in
aircraft and automobile components.
Contact: Prof. Dr. Paolo Ermanni
http://www.structures.ethz.ch/
ETH Zurich
Dept. Mechanical & Process Engineering
The Institute of Mechanical Systems (IMES) is committed to a long-term
sustainable development of our society by delivering cutting-edge and research
in the broad field of mechanics, structures and multifunctional materials. On
many axes of activities we consider systems from the small- to the large-scale,
from basic research to applications using theoretical, computational and
experimental approaches.
Research focuses among other things in the simulation of multi-body systems, in
the characterization of biological tissues, in micro and nanosystem technologies,
in the manipulation of micro particles by optimized fluid structure interaction, and
in material characterization through vibrations and ultrasound. Applied questions
like the curve squealing of rail vehicles, the fatigue of turbine components or
dynamic viscometry are also central.
Contact: Prof. Dr. Jürg Dual
http://www.imes.ethz.ch/
ETH Zurich
Dept. Mechanical & Process Engineering
Nowadays, complex manufacturing systems and -processes are virtually planned
before their realization. The Institute of Virtual Manufacturing deals with the
engineering of virtual systems, which support these planning processes. The
virtual mapping is treated in close dependence on industrial applications. Thus,
knowledge of real-life manufacturing processes, material behavior and control of
methods to evaluate process robustness pose important components of a virtual
planning process. These virtual methods are used in different modelling scales
depending on the needed application. Students are given the possibility to apply
learned engineering methods in the context of industry projects.
Contact: Prof. Dr. Pavel Hora
http://www.ivp.ethz.ch/
ETH Zurich
Dept. Mechanical & Process Engineering
NEWS
At its meeting of 17/18 September 2014, the ETH Board appointed
15 professors at ETH Zurich
Professor Dirk Mohr (*1976), currently Associate Professor at the Ecole
Polytechnique in Paris, France, and Research Affiliate at Massachusetts Institute
of Technology in Cambridge, USA, as Tenure Track Assistant Professor of
Computational Modelling of Materials in Manufacturing. Dirk Mohr conducts
research in the field of materials modelling. He develops his own material models
for plastic multiaxial deformation and ductile failure, including under high strain
rates. Dirk Mohr's expertise will complement the current research on materials
modelling in manufacturing processes and strengthen ETH Zurich's position in
this rapidly developing area.
ETH Zurich
Formula Student
Since the Academic Motorsports Club Zurich (AMZ) was founded in 2006 by
students of ETH Zurich it has produced a prototype to compete in various
«Formula Student» competitions in Europe every year. The association is
financially independent and supported by numerous financial, manufacturing and
parts sponsors as well as institutes of various Swiss universities. AMZ is the only
Swiss team in Formula Student.
The association offers students the opportunity to put their acquired
theoretical knowledge into practice in a highly complex engineering
environment. During this process they gather experience in the fields of
leadership, innovation and quality management, cost analysis, project and
product documentation as well as risk control.
EPF Lausanne
Mechanical Engineering
Laboratory of Applied Mechanics and Reliability Analysis (LMAF)
The research at LMAF is focused on the mechanics of solids and structures with
special emphases on damage and fracture of composites, reliability analysis,
contact mechanics, dynamics and biomechanics.
Contact: Prof. Dr. Ionnis Botsis
http://lmaf.epfl.ch/
EPF Lausanne
Materials Science and Engineering
Laboratory of Mechanical Metallurgy (LMM)
Research at the Laboratory of Mechanical Metallurgy addresses the science and
engineering of advanced metallic materials.
Our activities and interests span the entire spectrum from materials processing
to the exploration of links between the microstructure and the properties of
materials. Materials we study are made at least in part of metal and can be
destined for structural or for functional applications.
Our approach is largely but not exclusively experimental and touches upon a
number of subtopics of materials science. These include capillarity, infiltration,
powder densification, phase transformations including solidification, composite
and cellular materials, micromechanics, damage and fracture, dislocational
plasticity and creep, and the physics of conduction.
Contact: Prof. Dr. Andreas Mortensen
http://lmm.epfl.ch/
EPF Lausanne
Materials Science and Engineering
Laboratory of Composite and Polymer Technology (LTC)
Research topics
Cost and life cycle analysis of composites in transport applications
Evaluation of new polymers or composite processes
Out-of-autoclave processes for aerospace composites
Current projects
Cost and LC analysis of composites in transport applications
Evaluation of novel polymers for automotive applications
…
Contact: Prof. Dr. Véronique Michaud
http://ltc.epfl.ch/
Summary
Swiss Technical Universities
ETH Zurich
• Strong expertise in mechanical engineering and process
simulation
• Research in materials science is more fundamental and
not very industry-related
EPF Lausanne
• Basic coverage of mechanical engineering research
activities
• More industry-related research opportunities in the field of
materials science
Research TopicsSwiss Universities of Applied Sciences (UAS)
UAS Northwestern Switzerland
School of Engineering
Institute of Polymer Engineering (IKT)
Actual Projects
• Thin-Walled Composite Structures with Improved Damping Properties by using
Natural Fibre Composites and Thin Ply Carbon Fibre Technology (TwiCDamp)
• High performance composites with increased plasticity made from discontinuous
carbon fibre tapes with thermoplastic matrix (HICOMPLAST)
• Cost effective reinforcement of fastener Areas in composites (CERFAC EU-FP7)
Contact: Prof. Clemens Dransfeld
http://www.fhnw.ch/technik/ikt
UAS Northwestern Switzerland
School of Engineering
Institute of Product and Production Engineering (IPPE)
Research Areas
• 3D object scanning incl. 3D CAD modelling
• 3D laser micromachining
• FE analyses (mechanical, plastic flow, thermal)
• Mechanical testing of components (static, dynamic)
• Product and production engineering for aero- and space applications
• Rapid prototyping
• Failure and materials analyses
• Casting center
Contact: Prof. Dr. Jürg Küffer
http://www.fhnw.ch/technik/ippe
Zurich UAS
School of Engineering
Institute of Mechanical Systems (IMES)
Group Lightweight Design
Contact: Prof. Dr. Hanfried Hesselbarth
http://www.imes.zhaw.ch/
Institute of Materials and Process Engineering (IMPE)
Contact: Prof. Dr. Andreas H. Amrein
http://www.impe.zhaw.ch/
Centre of Product and Production Engineering (ZPP)
Contact: Adrian Burri
http://engineering.zhaw.ch/de/engineering/institute-zentren/zpp.html
UAS Eastern Switzerland
Engineering and Information Technology
Institute of Materials Technology and Plastics Processing (IWK)
The specialist competences of the IWK consist of materials (plastics, metals,
lightweight construction and composite materials), plastics constructions (calculations
and design), lightweight construction (composites, light metals, multi-material
structures, interconnection technology), process technology (process and tool
optimization: injection moulding, resin injection, thermoforming, etc.) and CAE
(simulation of component behaviour and production processes for product, tool and
process design; CAD, FEM).
Contact: Prof. Dr. Markus Henne
http://www.iwk.hsr.ch
Summary
Swiss Universities of Applied Sciences
Lightweight Design Activities
• Where?
UAS Northwestern Switzerland, UAS Zurich and UAS
Eastern Switzerland
• Mostly focused in composite materials
Focus on Implementation
• UAS research activities focus more in the implementation
at their industrial partners (so called “applied research
and development”)
Overview of Forms of Collaboration
R&D Guide 2014, Rev. 1 - Overview and
Tips to the Programs related to
Research, Development and Innovation,
53 pages
Price: CHF 145 (= EUR 120)
http://www.luedi-consulting.ch
Thanks for your
attention.