Case Studies for Additive Manufacturing Designs

Transcription

1 Case Studies for Additive Manufacturing Designs SME SMART Manufacturing Seminar Series August 10, 2017 Youngstown, OH Bianca Lankford Mechanical Engineer

2 Agenda Why AM? Key Enablers Case Study Examples Summary 16

3 Why use AM? Minimize production times Cost savings Lead time savings Rapid product development Reduce manufacturing steps Great for low-quantity builds Complexity is free! 17 AM can reduce cost and lead time for production assemblies

4 The AM Process: Art to Part Engineers design AM parts Print Rigorous analysis and/or test to reduce risk Program adoption (on PL) Qualification and certification processes Procurement processes AM parts in production 18

5 Use Cases for AM Brackets Ducts and plenums Coldplates Antennas Test Fixtures Rapid Prototypes 19

6 AM Enables Cost and Schedule Savings When properly utilized, Additive Manufacturing is a cost and schedule saver for: Rapid Build Cycle Reduce Parts Count Low Cost Iterations Complex & Affordable Design Freedom Convenience Schedule Compression Light Weight 20

7 We are invested in the future of AM Expand capabilities Further develop SMEs in AM Establish Sector COE s Factory of the Future Hybrid manufacturing capability Interconnected machines & automated handling using Co- Bots Develop fundamental capabilities Metal AM (Ti-6Al-4V, AlSi10Mg, etc.) Polymer Ongoing: Supply Chain partnerships Identify SMEs and train employees 21

8 Northrop Grumman AM Consortium Collaborative, multidisciplinary team that shares latest AM test data, resources and best practices across Northrop Grumman Corporation. Every sector is involved Aerospace Systems, Mission Systems and Technology Services Annual meetings and monthly working groups keep everyone in the loop 22

9 Key Enablers for NG Additive Manufacturing Engineering and Manufacturing expertise AM Consortium collaboration In-house capabilities Solid supply base partners University collaboration Iterate to Excellence 23

10 Case Study 1: G/ATOR Cable Clamp

11 What is G/ATOR? AN/TPS-80 Ground Air Task Oriented Radar A new S Band multi-mission radar Northrop Grumman has developed for the U.S. Marine Corps. The first multi mission ground radar developed by the U.S. Department of Defense: An unprecedented combination of operational capabilities Multi-threat capable Detects and tracks a broad range of airborne threats Fixed wing & rotary wing aircraft, Unmanned Autonomous Systems, cruise missiles, rockets/artillery/mortars Provides a precise, real time, actionable, integrated air picture, even in complex operational scenarios. Easily deployed due to expeditionary design (lightweight and mobile) Largest radar program in U.S. Marine Corps history: Total program value exceeds $2B DOD investment to date exceeds $550M The primary radar that the Marine Corps will utilize worldwide for the next 30+ years. 25 An unprecedented combination of Operational Capabilities

12 G/ATOR cable clamps Design challenges Robust AM solution We iterate to excellence Reduce risk 72% cost savings over machined Delrin (subtractive mfg) Lessons learned G/ATOR 26

13 G/ATOR Cable Clamps Risk Mitigation VSWR (db) For various compression amounts The work done to burn down the risk includes the following: From an June 2 nd announcing AM Insertion into G/ATOR Multiple iterations of part builds with different materials, different sizes, and different machines to find an optimized design to meet requirements Mechanical fit checks using hardline cables to ensure cable clamping and mechanical integrity of the design (functionality maintained, parts don t break, etc) is optimized RF analysis to ensure the parts do not over clamp the RF hardline cables and that the cables will still meet expected performance Temperature cycle testing (-40 C to +71 C) Creep testing and comparison to machined Delrin clamps Detailed tolerance studies to ensure same functionality to machined Delrin clamps is achieved Increased the size of the washers that secure the parts in place to ensure sufficient bearing area to overcome hole deformities Created a structural FEM of the cable. Used the FEM to determine the max clamping load that keeps the RF characteristic impedance of the cable within tolerance limits (50 +/- 5 ohms) 27 Significant Risk Reduction Builds, Testing & Analyses Completed!

14 G/ATOR Cable Clamps with #2, #4, #6 & #8 Screws inserted.086 Ø.112 Ø #2=.086 Ø #4=.112 Ø #6=.138 Ø #8=.164 Ø.086 Ø.112 Ø.136 Ø Ø.136 Ø.164 Ø

15 DoE Summary Test Plate Designed to Simulate Production Installation of G/ATOR AM Cable Clamps Used Production Screws and Standoffs Replicated Production Configurations Tested 34 Production Parts in Total 19 Tested on Standoffs, 15 Tested on Flat Plate Torque Applied Incrementally from 1 to 7 in-lbs. Maximum Survivable Torque and Failure Torque were Recorded Planar/Mounting Max Survivable Torque (inlbs) (in-lbs) Tested From Failure Torque Date Parts Sample # PN Flat/Standoff? Notes Hole? Mounting Standoff 3 4 1/30/2017 Kitted Marked 8--one we tested in RR's office 1 H47 Planar Standoff 5 6 1/30/2017 Kitted Mounting Flat 6 7 1/30/2017 Kitted 2 H47 Planar Flat 9 N/A 1/30/2017 Kitted 3 H46 Planar Flat 9 N/A 1/30/2017 Kitted Screw broke at 10 in/lbs 4 H45 Planar Standoff 7 N/A 2/2/2017 Stores 5 H45 Planar Flat 7 N/A 2/2/2017 Stores 6 H45 Planar Standoff 7 N/A 2/2/2017 Stores 7 H45 Planar Flat 7 N/A 2/2/2017 Stores 8 H45 Planar Standoff 7 N/A 2/2/2017 Stores 9 H45 Planar Flat 7 N/A 2/2/2017 Stores 10 H45 Planar Standoff 7 N/A 2/2/2017 Stores 11 H45 Planar Flat 7 N/A 2/2/2017 Stores 12 H45 Planar Standoff 7 N/A 2/2/2017 Stores 13 H45 Planar Flat 7 N/A 2/2/2017 Stores 14 H45 Planar Standoff 7 N/A 2/2/2017 Stores 15 H44 Planar Flat 7 N/A 2/2/2017 Stores Being tested in timed torque test 16 H44 Planar Standoff 7 N/A 2/2/2017 Stores 17 H44 Planar Flat 7 N/A 2/2/2017 Stores 18 H44 Planar Standoff 7 N/A 2/2/2017 Stores 19 H44 Planar Standoff 7 N/A 2/2/2017 Stores Being tested in timed torque test 20 H46 Planar Flat 7 N/A 2/2/2017 Stores 21 H46 Planar Standoff 7 N/A 2/2/2017 Stores 22 H46 Planar Flat 7 N/A 2/2/2017 Stores 23 H46 Planar Standoff 7 N/A 2/2/2017 Stores 24 H46 Planar Standoff 7 N/A 2/2/2017 Stores Mounting Flat 4 5 2/2/2017 Stores 25 H47 Planar Flat 7 N/A 2/2/2017 Stores Mounting Standoff 4 5 2/2/2017 Stores Left mounting hole broke 26 H47 Planar Standoff 7 N/A 2/2/2017 Stores Mounting Flat 4 5 2/2/2017 Stores Left mounting hole broke at 5, Right mounting hole broke at 7 27 H47 Planar Flat 7 N/A 2/2/2017 Stores Mounting Standoff 3 4 2/2/2017 Stores Left mounting hole broke, small crack starting at 4, full crack going to 5 in-lbs 28 H47 Planar Standoff 6 7 2/2/2017 Stores 29 H44 Planar Standoff 7 N/A 2/3/2017 Kitted 30 H45 Planar Standoff 7 N/A 2/3/2017 Kitted 31 H46 Planar Standoff 7 N/A 2/6/2017 Kitted Mounting Standoff 4 5 2/6/2017 Kitted Both mounting holes broke 32 H47 Planar Standoff 6 7 2/6/2017 Kitted Broke between mounting holes 33 H44 Planar Flat 7 N/A 2/6/2017 Kitted 34 H45 Planar Flat 7 N/A 2/6/2017 Kitted 29 Test Results Support Analyses Predictions of Added Stress from Standoffs

16 Case Study 2: G/ATOR Air Duct

17 ASE Air Ducts Designed multiple prototypes Re-designed for AM 3 pieces into 1 More lightweight 60% cost savings ($26k to $10k) 31

18 PEKK Insertion into production: ASE Air Ducts EMI Filter AM DESIGN OPTIONS Integral AM air duct Bracket Air Duct EMI Filter No Bracket OR AM Air Duct Air Duct 32 Baseline Design: Brazed Aluminum $26K per air duct pair Two ducts, One EMI Filter/One Bracket AM Design: PEKK- Carbon Filled $10K per air duct pair Bracket Removed One duct & one external EMI Filter Northrop APPROVED Grumman Corporation FOR PUBLIC Private RELEASE / Proprietary Level 1 AM Design: PEKK- Carbon Filled $9.6K per air duct pair Bracket removed One duct: Plated/Painted

19 Case Study 3: Aluminum Coldplate

20 Existing Design vs. AM Design: Models FRONT VIEW Cold Plate Rail Heat Generating Card Wedge Clamp Traditional location for brazed-finned cooling passages Finned passages printed in rails 34

21 Conclusion We tackle complex problems with Iterate to Excellence as our motto Creating AM solutions for: On the ground In the air Undersea / on the sea In space Exciting future ahead! 35

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23 Backup Content

24 G/ATOR One Material Solution Doing the Job of Multiple Radars for Maximum Operational Flexibility Air Defense/SHORAD Air Surveillance Possible Future Mission: TBM Detection/Tracking Counterfire Target Acquisition Air Traffic Control Unprecedented Multi-Mission Capabilities in a Single Radar 38

25 Northrop Grumman Mission Systems Is a trusted provider of mission-enabling solutions for global security Is committed to unmatched performance excellence in C4ISR and cyber solutions Has a wide portfolio of secure, affordable, integrated, and multi-domain systems and technologies 39 Mission-Enabling Solutions

26 Mission Systems Sector Today Leading global provider of secure software-defined, hardwareenabled mission systems $10.7* billion sales in ,000 employees In all 50 U.S. states and 21 countries Pioneering capabilities in: Full-Spectrum Cyber End-to-End & Integrated C4ISR Innovative Integrated Solutions Mission Effectiveness from Undersea to Space and Cyberspace Mission-Enabling Solutions 40 *IS and ES Approximation

27 Mission Systems From Undersea to Outer space Advanced Concepts & Technologies Airborne C4ISR Systems Division Cyber and Intelligence Mission Solutions Division Land & Avionics C4ISR Division Missile Defense and Protective Systems Division Navigation and Maritime Systems Division Space ISR Systems Division 41 Cyber & Advanced Processing Surveillance & Targeting Sensors Multifunction Systems Integrated Solutions Transformational Computing Advanced Microelectronics Fire Control Systems Surveillance Systems Electro Optical Systems Targeting Systems Communications SIGINT Systems Air C2 & Airborne ISR Electronic Attack Targeting and Weapon Planning Intelligence Acquisition & Analytics Cyber Resiliency Cyber Defense Cyber/Non-Kinetic Operations Intelligence Enterprise Integrated Aircraft Survivability Equipment Multi-Spectral Electronic Warfare Systems Integrated Avionics Suites C2 ERP Systems Global Mission Solutions C2 for Missile Defense, IAMD, Nuclear Systems and Land Forces Strategic Ground Systems BMDS Integration, Testing Training, and Readiness Support Integrated Fires Civil Aviation Planning and ATC Civil C2 for Emergency Responders Propulsion & Power Systems Cold Launch Maritime Electronic Warfare & Radars Maritime C2 Machinery Control Systems Undersea Sensors & Solutions Navigation & Positioning Systems International Navigation & Pointing Solutions Restricted Programs RF Systems EO/IR Solutions Ground Enterprise SSA & Space Operations Environmental Solutions Integrated Solutions Space C2 Exploitation Processing OPIR/SIGINT/GEOINT

28 AM Virtual Collaboration 42

29 Abstract and Bio

30 Abstract Recent advancements in 3D printing technologies have opened up a new world for engineering design. Custom parts are being designed faster than ever, and with decreased lead times from their subtractively manufactured counterparts. Additive Manufacturing (AM) also supports rapid iteration of parts, reducing the product development life cycle time and cost. AM is especially popular with low-quantity builds, due to the drastic reduction of casting molds, fixtures, machining time and manufacturing steps. All of these advancements provide a unique opportunity for Northrop Grumman Mission Systems to incorporate AM parts into our products and manufacturing processes. This presentation will include case studies of 3D printed parts and examples of the materials utilized. 44

31 Speaker Bio Bianca Lankford is a mechanical engineer at Northrop Grumman Mission Systems in Baltimore, MD. She is a thermal analyst, Additive Manufacturing SME and manager of the Technology Underground innovation lab. In addition, Bianca leads the Design for Additive Manufacturing (DFAM) team and cochairs the AM Polymers working group. She has published 7 papers on Additive Manufacturing at Northrop Grumman and received multiple IP awards for her contribution to the technology. Bianca lives in Baltimore, MD with her husband, James, and their puppy, Daisy. 45