CT leads the Remedi project to establish a design methodology for large components for the aerospace sector

18.07.19

CT leads the Remedi project to establish a design methodology for large components for the aerospace sector

A few weeks ago, CT celebrated at its headquarters in Getafe the kick-off meeting of the Remedi R&D project, an initiative endorsed by the Smart Eureka Advanced Manufacturing call.
The project aims at establishing an optimal, efficient and light design methodology in the manufacture of medium- large components, making the most of the capabilities of the ‘Additive Manufacturing by Direct Metal Deposition’ technology through laser technology and contribution of metallic powder.
This ambitious initiative is the result of an international collaboration between various Spanish partners- CT, Ramem, Smarmec and AIMEN Technological Center - and Turkish ones - Coşkunöz R & D and TAI (Turkish Aerospace Industries), a handful of multidisciplinary companies to cover the entire project value chain.

The Remedi R&D project aims at overcoming some of the current barriers on design optimization and productivity in the digital manufacturing of medium-large high-added value components, manufactured by laser metal deposition technologies, seeking a better acceptance of this technology. The value chain of these processes comprises design, process configuration, process planning, manufacturing with online control / monitoring, postprocessing, and quality control, yet it is the redesign stage the one that offers the highest added value and the most relevant benefits. Therefore, REMEDI focuses on using these different manufacturing stages to provide feedback to the design itself, up to its most efficient optimization.

To implement the Quality-by-Design (QBD) concept in the prototypes manufacturing, a software / hardware platform will be used. This will consist of an offline engineering unit, which integrates under the same layer different commercial CAx technologies and a physical installation of additive manufacturing by LMD, to implement a Quality by Design methodology and validate it for the additive manufacturing of large components optimized to achieve zero defects.

This software environment will be implemented in two manufacturing factories- Smarmec and Coskunoz R&D, to prove the concept and achieve future reproducibility in any demanding industry. The REMEDI technology will be validated for two different sectors demanding high added value components: space applications and aircraft components.

The project will approach a series of technological milestones to achieve its goals:

• Performing a topological optimization of the piece design based on the requirements of structural integrity and functional loads, to provide a more efficient component in terms of raw material use, manufacturing costs and delivery time.

• Determining the manufacturability capabilities of the LMD process in its different configurations of equipment parameters or process parameters, in order to provide the Topological Optimization tool with data from real industrial scenarios.

• Acting on the system configuration / deposition strategies / multiphysics simulation cycle to reach a thermal equilibrium, which allows an automatic evaluation of the piece design obtained in the previous steps, while detecting those areas of the piece that may not be proper for its manufacture or for the final functionality of the piece.

• Analyzing the data linked to the laser power and the temperature of the molten bath at any point in the process path through monitoring systems, in order to link them to the design stage and propose new design changes based on this.

About Remedi

The REMEDI project lasts 30 months (it is expected to end in 2021) and has an approximate budget of € 2M. The international project has been approved under the SMART EUREKA Advanced Manufacturing call. At the national level, the project is subsidized by the CDTI through the INNOGLOBAL 2018 program, and supported by the Ministry of Science, Innovation and Universities with a total budget of € 1,335,516.00, and a total aid of € 392,657.00 .

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