Additive-Manufactured Conduit Coil for Large Flow Cross Sections
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Solution Overview
Problem
Producing a blank of a line arrangement with multiple turns in an axial direction using a generative manufacturing process is challenging due to material loss and the difficulty in forming large throughflow cross sections and inclined surfaces, which require complex supporting structures.
Innovation Solution
A blank with an annular line formed by a channel enclosed by a wall, where the wall has areas that do not contact the base area and are inclined at specific angles, allowing for the production of turns with a throughflow cross section that can be produced layer by layer using a generative manufacturing process, with a supporting structure that is materially bonded and removable to minimize material and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a line arrangement with multiple turns and large throughflow cross sections is produced by generative manufacturing, then material loss is reduced and production efficiency is improved, but the complexity of supporting structures increases and manufacturing precision becomes more difficult to achieve
Solution Approach 1:
The line arrangement is divided into multiple turns that are arranged adjacently in the axial direction, allowing the generative manufacturing process to build the structure layer by layer. This segmentation enables the creation of complex three-dimensional geometries without requiring excessive supporting material, as each layer is built upon the previous one.
Solution Approach 2:
The line arrangement extends in the circumferential direction over more than 360 angular degrees and forms multiple turns arranged in the axial direction. By utilizing the axial dimension for turn arrangement rather than planar expansion, the design achieves large throughflow cross sections while minimizing the need for complex supporting structures during generative manufacturing.
2Productivity
If turns are arranged adjacently in axial direction with large throughflow cross sections, then productivity is improved, but manufacturing precision becomes more difficult to achieve
Solution Approach 1:
The wall of the line arrangement is designed with specific angular parameters: first areas are arranged at a first angle of at least 30 angular degrees with respect to the base area, and surface normals form second angles of from 0 to 60 angular degrees with respect to the base area. These controlled angular parameters enable the generative manufacturing process to achieve the required manufacturing precision for inclined surfaces while maintaining high productivity.
3Ease of manufacture
If wall areas are inclined at specific angles to the base area, then ease of manufacture is improved, but the structural stability may be compromised
Solution Approach 1:
The wall is designed with different local geometries: first areas that are inclined at specific angles for ease of manufacture, and second areas that provide structural support. This local differentiation allows regions requiring ease of manufacture to have optimized angles while other regions maintain structural stability, resolving the contradiction between manufacturability and structural integrity.
Data Source
AI summary
A blank for a conduit arrangement includes an annular conduit having a first end and a second end, which is formed by a channel surrounded by a wall. The conduit arrangement has an axis of rotation and the conduit extends in a circumferential direction over an angle of more than 360 degrees about the axis of rotation and forms at least one wind turn. The axis of rotation is arranged perpendicularly to a base surface, the wall having first surfaces which are arranged at a first angle of at least 30 degrees relative to the base surface or in which a surface normal forms at least one second angle of 0 to 60 degrees with respect to the base surface. First partial surfaces of the walls, which face one another in an axial direction, of adjacent turns are arranged spaced apart from one another. The blank is produced by an additive manufacturing process.