Topology optimization of highly stressed machine tool components using the SLM process

Additive manufacturing (AM) processes have become increasingly important in recent years. Their application enables the manufacturing of individual, functional components using minimal material. In particular, AM processes are used for the manufacturing of lightweight structures in the aerospace industry. Apart from rare exceptions, the use of additively manufactured components in machine tools is not widespread. However, their functional lightweight design offers high potential for increasing productivity of machine tools. This potential is particularly high when components are frequently accelerated due to the possibility of reducing moments of inertia. This paper presents a concept of a topologically optimized, rotating, and mechanically high stressed lathe clamping system using the SLM (Selective Laser Melting) method. The topology optimization is performed numerically with the simulation software ANSYS. The additive materials applied are a stainless martensitic chrome-nickel steel (AISI 630) and an aluminum-silicon alloy (EN AC-43000). First, strength-relevant material characteristics are determined experimentally. The effects of different hardening processes on the material characteristics are predicted. These material properties are required for the parameterization of the clamping system simulation model. The modelling approach is described in the following. The simulation results of the non-optimized clamping system serve as a reference for evaluating the properties of the optimized system. The simulation model is then used to perform a mass-based topology optimization of four components of the clamping system with high moments of inertia. The components are evaluated simulatively with regard to their yield strength. As a result of the topology optimization, it is found that the moments of inertia of the components are reduced by up to 72%. Due to the functional, lightweight design of the clamping system, significant reductions in machining and non-productive time of up to 19% are possible.