|Tipo di tesi||Tesi di laurea magistrale|
|Titolo||Metodo di automazione della progettazione per componenti di manifattura additiva: riprogettazione di pezzi di ricambio di manifattura convenzionale.|
|Titolo in inglese||Design automation method for additive manufacturing components: re-design of conventional manufacturing spare parts.|
|Struttura||Dipartimento di Ingegneria "Enzo Ferrari"|
|Corso di studi||Advanced Automotive Engineering (D.M.270/04)|
|Data inizio appello||2022-10-20|
|Disponibilità||Embargo di 3 anni|
|Data di rilascio||2025-10-20|
Questo lavoro nasce dalla collaborazione tra BEAMIT e Sandvik Mining e Rock Technology per la riprogettazione di centinaia di pezzi di ricambio di produzione convenzionale delle macchine minerarie Sandvik da produrre attraverso la produzione additiva. L'obiettivo di Sandvik è ridurre i tempi di consegna, sviluppando al contempo capacità ingegneristiche ed esperienza nel campo della produzione additiva.
This work is born from the collaboration between BEAMIT and Sandvik Mining and Rock Technology for redesigning hundreds of conventional manufacturing spare parts of the Sandvik mining machines to be produced through additive manufacturing. The Sandvik goal is reducing lead times, while developing engineering skills and experience in the additive manufacturing field. Traditional design methods, previously employed in BEAMIT, are too laborious to handle large amounts of components at once in a tight deadline, hence the need for a new innovative method, which has to be more efficient and as automated as possible. After a literature review of design and structural optimization methods, like topology optimization and generative design methods, an analysis has been carried out on the softwares and modelling technologies available on the market using a benchmark. A score, as the sum of accurately chosen and weighted parameters, has been assigned to each software and the most suitable for the project needs have been selected to define a new design process workflow: most of the parts are going to be designed in an automated way, exploiting nTopology implicit modelling technology alongside the CAD environment of Fusion 360 as support, while few simple parts are designed on Fusion 360 alone through application of literature theoretical results and FE analysis. An automated design method capable of assigning boundary conditions, compute a FEM baseline study, run one or several topology optimization, reconstruct a smooth geometry, re-run FEA and export CAD model and 3MF model has been developed. Few case studies implementing in practice this design process are shown and the effect of design elements like lattice structures, conformal surface ribbing and fillets are discussed with focus on the industrialization of such case study parts. Results on the effects of the automated design method on productivity and manufacturing are discussed and insights on future perspectives are exposed.