Metal Underframe Additive Filler Structure for Weight and Stress Control
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Solution Overview
Problem
Conventional base frames for machines and systems lack application-specific optimization, leading to inefficiencies in absorbing static and dynamic forces, material wastage, and weight, with limited control over stress peaks and dynamic analysis.
Innovation Solution
Integration of additive sections, particularly filler structures, into metallic base frames using additive manufacturing processes, which are designed to optimize mechanical properties and reduce weight while enhancing force absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional base frames are used, then manufacturing simplicity is maintained, but material efficiency and weight optimization are insufficient
Solution Approach 1:
The base frame is divided into conventional sections and additive sections, allowing different manufacturing approaches for different functional requirements. The additive sections contain filler structures with optimized material distribution, while conventional sections maintain simple manufacturing processes.
Solution Approach 2:
Additive manufacturing is applied locally to specific sections of the base frame where complex geometries and optimized material distribution are beneficial, rather than manufacturing the entire frame additively. This allows material efficiency improvements in critical areas while maintaining overall manufacturing simplicity.
2Weight of stationary object
If conventional base frames are used, then manufacturing simplicity is maintained, but weight reduction is limited
Solution Approach 1:
Filler structures with porous or lattice geometries are manufactured additively within frame sections, reducing material density while maintaining structural integrity. These porous structures provide weight reduction while preserving the necessary mechanical properties for force absorption.
Solution Approach 2:
The filler structures introduce complex three-dimensional geometries within the frame sections, creating optimized material distributions that reduce weight while maintaining strength. The additive manufacturing process enables these complex 3D structures that cannot be achieved with conventional manufacturing.
3Manufacturing precision
If conventional base frames are used, then structural simplicity is maintained, but control over stress peaks and dynamic behavior is limited
Solution Approach 1:
The additive sections with filler structures are strategically placed in areas requiring optimized stress distribution and dynamic behavior control. The complex geometries of the filler structures are designed to specifically address stress concentration points and improve dynamic characteristics in critical regions.
Solution Approach 2:
The base frame combines conventional metal sections with additively manufactured filler structures, creating a composite structure that leverages the advantages of both approaches. The filler structures provide optimized stress distribution and dynamic behavior, while the conventional sections maintain structural simplicity.
Data Source
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AI summary
A subframe (6) for a system (2) contains frame components (8a-e) made of metallic material, wherein at least one of the frame components (8a-e) contains at least one additive section (10) that is at least partially manufactured using an additive manufacturing process, wherein at least one of the additive sections (10) has a frame (12) and an additively manufactured filler structure (20) that is permanently and firmly connected to the frame (12) and that passes through a free space (18). A system (2) contains the subframe (6) and system components (4a-c) that are permanently and permanently attached to the subframe (6) in an assembled state. In a method for producing the subframe (6), at least one additive section (10) is produced for at least one of the frame components (8a-e) by additively manufacturing the filler structure (20) and permanently and firmly connecting it to the frame (12), thereby passing through the free space (18).