Design for additive manufacturing: integration of procedures and simulation tools

• Grant number: 23/17682-9
• Support Opportunities: Scholarships in Brazil - Post-Doctoral
• Start date: March 01, 2024
• End date: February 28, 2026
• Field of knowledge: Engineering - Aerospace Engineering
• Principal Investigator: Alfredo Rocha de Faria
• Grantee: Rodrigo Martins Farias
• Host Institution: Divisão de Engenharia Mecânica (IEM). Instituto Tecnológico de Aeronáutica (ITA). Ministério da Defesa (Brasil). São José dos Campos , SP, Brazil
• Company: Ministério da Defesa (Brasil). Instituto Tecnológico de Aeronáutica (ITA). Divisão de Engenharia Mecânica (IEM)
• Associated research grant: 21/11258-5 - Engineering Research Center for the Aerial Mobility of the Future (ERC-AMF), AP.PCPE

Abstract

The main objectives are: (i) development of the design for additive manufacturing (DfAM) applicable to typical aeronautical structural components that will be fabricated through additive manufacture, (ii) planning of the fabrication schedule using L-PBF, post-processing and inspection, (iii) creation and execution of numerical models to predict distortions and residual stresses along the metallic AM chain of complex geometries in aerospace components. Among these activities one may cite heat treatment cycle, wire electrical discharge machining (EDM) and conventional machining processes. The numerical results will be confronted against experimental results obtained from the inspections along the processing chain. The performance of the structural part fabricated by AM within the context of aerospace applications must also be analyzed. A guide for good practices to AM, reporting limitations and possible enhancements of the schedule planning, must be elaborated. (AU)