Easyworks Project: Amodiño

LAUNCH 2018

The main objective of the AM0DIÑO project is the development and implementation of a methodology for (re)design and manufacturing oriented towards digital and efficient zero-defect production of large-sized and high added-value components in steel and bronze for the capital goods and shipbuilding sectors. The concept of efficient and digital manufacturing will focus on Direct Energy Deposition Additive Manufacturing (DED-AM).

Specifically, the project addresses two main technologies: Laser Metal Deposition (LMD) and Wire Arc Additive Manufacturing (WAAM), as they offer high processing flexibility, high metal deposition rates, and the use of well-known installations within the metal-mechanical sector.

The project arises from the need of many companies to manufacture or repair medium-large components for different sectors such as capital goods, machine tools, shipbuilding, or wind energy. Using conventional technologies, they face competition from developing countries, which is difficult to overcome in terms of price and delivery time due to more relaxed environmental regulations and lower labour costs. The only way to remain competitive is to shift towards production processes that consume fewer resources and less time, while obtaining a higher value-added product with greater profit margins. Increasing the competitiveness of the Galician industrial sector inevitably requires its “reinvention”, through the search for new production methods that enhance competitiveness.

In this sense, one of the technologies that has most contributed to the reinvention of production processes in recent years is Additive Manufacturing (AM), which has become a key enabling technology for the industry of the future. While powder-bed AM has experienced the greatest progress in recent years, DED-AM technologies present strong industrial application potential.

Their main advantage lies in their higher deposition rate and therefore their scalability to large components, multiplying design possibilities and enabling optimised components from a material saving and structural behaviour perspective, providing significantly higher added value.

UPDATE 2019

Technological challenges
Development of a topology optimisation procedure for industrial components to be manufactured by DED-AM, based on automatic manufacturability and structural integrity assessment during the design phase.

Process preparation and manufacturing of selected components, including optimisation of manufacturing parameters, development of CAM tools and process control tools to manufacture components with required structural quality and minimum raw material usage.

Validation and feasibility study of components obtained through Additive Engineering, ensuring competitiveness in terms of price and delivery time.

During the last year, work has been carried out to achieve the above challenges, as detailed below:

Development of topology optimisation procedure:

1. Definition of manufacturability criteria. Manufacturability criteria associated with LMD and WAAM technologies have been defined as boundary conditions for redesigning demonstrators.
2. Definition of structural integrity criteria. Required tests have been defined to characterise deposited materials. Results are used for redesign of structural components.
3. Link with topology optimisation tool. A file structure including LMD and WAAM manufacturability information is being defined to connect with topology optimisation software. A database is being created to store this information and allow access from the software.
4. Redesign of structural components. Suitable software has been selected and initial simulations have been performed considering service conditions.

Process preparation and manufacturing of components.

1. Process parameterisation. Optimal parameter windows have been defined for LMD (MSEOANE demonstrator) and WAAM (FADRÍO and THUNE EUREKA demonstrators).
2. Process planning (secondary redesign). Toolpath planning has been initiated considering geometry constraints and manufacturing requirements.

UPDATE 2020

During this year, work has continued on the following areas:

Development of topology optimisation procedure:

• Definition of manufacturability criteria. A database has been created containing all manufacturability information generated during the project. This information is structured into manufacturability sheets defined in the previous year. This database feeds the topology optimisation software with data required to design DED-manufacturable parts while minimising material usage and ensuring service requirements.
• Definition of structural integrity criteria. The defined tests have been executed and the results have been used to feed FEM simulation of the topology-optimised components.
• Link with topology optimisation tool. A software application has been developed to connect LMD and WAAM manufacturability data with topology optimisation software. This enables designers to improve component design with proper support for DED manufacturability.
• Redesign of structural components. Topology optimisation has been carried out on the three selected components considering service conditions, aiming to reduce weight while maintaining or improving functionality.

Process preparation and manufacturing of components.

• Process parameterisation: Optimal parameter windows have been established for both LMD and WAAM processes applied to the selected components. Necessary tests have been performed to fine-tune these parameters and analyse process capabilities and limitations.
• Process planning (secondary redesign). Thermal and mechanical simulation models have been developed for components and simplified geometries. Multi-physics simulation results are currently being analysed to refine manufacturing strategies and designs.

CONSORTIUM AM0Diño

To address this ambitious challenge, a multisector consortium of six Galician SMEs has been established:

UNIMATE, THUNE EUREKA, FUNDICIONES ADRIO, MAXIMINO SEOANE, AIMEN

EASYWORKS is the project coordinator, with its main role focused on redesign and process planning for additive manufacturing through the development of CAx technologies.

UNIMATE is applying its expertise in turnkey industrial cells to develop the FADDE cell at THUNE EUREKA.

THUNE EUREKA is developing the FADDE cell in collaboration with UNIMATE for manufacturing large tooling for internal use.

FUNDICIONES ADRIO is developing new propeller designs enabled by AM, including a WAAM-optimised blade.

MAXIMINO SEOANE is working on manufacturing a gas extraction wheel using AM, replacing several manufacturing operations with a single one. It is also expanding its engineering capabilities in AM design and manufacturing.

The consortium is supported by the technology centre AIMEN, with extensive experience in advanced manufacturing processes and additive manufacturing technologies.

PROJECT FUNDING:

The AM0DIÑO project, under the CONECTAPEME 2018 programme, is funded by the Xunta de Galicia through GAIN and the Consellería de Economía, Emprego e Industria, and co-financed by the European Regional Development Fund (ERDF) under the Galicia Operational Programme 2014–2020.