The energy turnaround on the one hand and the increased sense of responsibility towards future generations on the other hand, lead to a growing awareness of the limitation of natural resources. Here, lightweight systems can make an effective contribution by reducing the energy demand by means of a significant reduction of moving masses.
In this context, system lightweight engineering in multi-material design has proven to be very promising. Depending on the requirements, all material classes from fiber-reinforced plastics to metals as well as ceramics can be used in combination with each other according to their properties profile. The design process of such hybrid lightweight structures is marked by a complex interaction between design, simulation and production and in practice is often characterized by an iterative trial and error procedure.
The aim of AMARETO’s sub-project Smart Design, which is located at TU Dresden, is to validate existing as well as still to be developed new modeling methods for the creation of suitable geometry, material and process models. Then these models are merged towards a coupled process-structure-analysis in the sense of modifiable modular sub-models. Using the calculated material and component structure resulting from the production process, the structural behavior is determined by an integrative structural analysis and evaluated according to the functional requirements of the component.
The obtained project results are used for a purposefully adaptation of the production process, as well as the materials and the geometry, in order to optimize simultaneously the production processes and the macroscopic structure. The needed material input data and models will be provided by the sub-project Smart Material. Information on component and process design will be fed into the sub-project Smart Production for an efficient development of resource-friendly production processes.
