Dr. Schneider, Maassen & Kass on CASCON 2019: Design and fatigue resistant design of an SLM-manufactured bicycle crank and validation with the component test

The presented work shows the design finding of a bicycle crank manufactured in the SLM process under consideration of measured material fatigue properties and the fatigue loading from service. The design procedure is finally validated by fatigue testing the component on a pulsator.

The start is the topology optimization in ANSYS Mechanical, which provides ideas for the basic shape and, in particular, reveals structural-mechanical relationships within the component. A parameter study with a parameterized CAD model of this basic shape gives the optimal cross-sections and wall thicknesses with regard to the considered load cases. The design and notch stress reduction under consideration of the manufacturing process used is carried out by means of ANSYS SpaceClaim and ANSYS Mechanical. nCode inside ANSYS enables a lifetime estimation of the bicycle crank. The required material fatigue data for the used material AlSi10Mg are determined by bending fatigue tests on suitable specimens. A component test on a servo-hydraulic test bench is used to validate the service life estimate.

The production of the components using the SLM method is prior to the component test. In order to guarantee a build up without recoater crash, failure of supports and other defects, the manufacturing process was simulated in advance. This also provides insights into the design of the supports that are indispensable for the SLM process.

Session: "Strukturmechanik - Additive Fertigung 172"

October 16th, 2019 / 16:15-16:45