Proceedings of the Munich Symposium on Lightweight Design 2021: Tagungsband zum Münchner Leichtbauseminar 2021

Preface
Contents
About the Editors
Efficient Computation of Spatial Truss Structures for Design Optimization Approaches Using Tube-Shaped Thin-Walled Composite Beams
	1 Motivation
	2 Thin-Walled Composite Beam Theory
	3 Element Stiffness Matrix
	4 Numerical Examples
	5 Conclusion
	References
Substitution of Strain Gauges by Optical Strain Measurement for Standard Test Methods of Composite Specimens and Introduction of a New Biaxial Test-Fixture
	Abstract.
	1 Introduction
	2 Testing
		2.1 Specimen Manufacturing
		2.2 Test-Setup
		2.3 Test Results
		2.4 Evaluation and Comparison of Strain Measurement Methods
		2.5 Conclusion
	3 Biaxial Test-Fixture
	4 Summary and Outlook
	References
Investigation and Modelling of Machining Processes as Surface Pre-treatment for Structural Adhesive Bonding of CFRP
	Abstract.
	1 Introduction
	2 Experimental
		2.1 Materials and Processes
		2.2 Testing and Surface Analysis
		2.3 Simulation and Quick Stop Experiment
	3 Results
		3.1 Surface Characterization and Testing of Bonded Specimen
		3.2 Investigations on Microscale Chip Formation
	4 Discussion and Conclusions
	5 Summary
	References
In-Mold Coating in Pressing of Natural-Fiber-Reinforced Salt Cores for High-Pressure Die-Casting Applications
	Abstract.
	1 Introduction
	2 Materials and Methods
		2.1 Materials
		2.2 In-Mold Coating and Compression Molding of Natural-Fiber-Reinforced Salt Cores
		2.3 High-Pressure Die-Casting
		2.4 Examination Methods
	3 Results & Discussion
		3.1 Durability of the In-Mold Coating
		3.2 Degradation of Flax Fibers
		3.3 Cleanliness and Roughness of Cores and Casting Parts
	4 Conclusion
	References
Compressibility and Relaxation Characteristics of Bindered Non-crimp-Fabrics Under Temperature and Injection Fluid Influence
	Abstract.
	1 Introduction
	2 Compressibility Measurement
		2.1 Novel Test Rig
		2.2 Textile
		2.3 Methodology
			Compressibility Measurements.
				Dry Compaction Measurement at Room and Elevated Temperature.
				Combined Dry and Wet Compaction Measurements (in-situ Saturation Measurements).
			Binder Analysis.
				TGA/DSC-measurements.
				Rheology Measurements.
				Microscopy Measurements.
	3 Results
		3.1 Compressibility Measurements
			Compressibility of bindered textiles.
			In-situ Saturation Measurements.
		3.2 Binder Analysis
	4 Discussion and Conclusion
		4.1 Compaction Measurements
		4.2 Binder Analysis
	References
Determination of the Bending Stiffness of Spread Carbon Fibre Tows Applied with Reactive Binder
	1 Introduction
	2 Material and Methods
		2.1 Cantilever
		2.2 Optical Test Arrangement
	3 Bending Stiffness
		3.1 Cantilever Reference
		3.2 Optical Test Arrangement
		3.3 Temperature Variation
	4 Numerical Approach
		4.1 Model and Material
		4.2 Results
	5 Conclusion
	References
Manufacturing Technologies for Box-Shaped Pressure Vessels with Inner Tension Struts
	Abstract.
	1 Introduction
		1.1 Motivation
		1.2 State-of-the-art
		1.3 Concept of a box-shaped pressure vessel with inner tension struts
	2 Manufacturing concepts
		2.1 Differential pressure vessel design
		2.2 Integral pressure vessel design
	3 Manufacturing of Prototypes
		3.1 Tufting
		3.2 3D-weaving
	4 Prototype testing
	5 Industrialisation
		5.1 Tufting process qualification for series production
		5.2 Weaving process qualification for series production
	6 Summary and Outlook
	References
Multi-Objective Topology Optimization of Frame Structures Using the Weighted Sum Method
	Abstract.
	1 Introduction
	2 State of the Art
	3 Multi-Objective Element Stiffness Matrix in Topology Optimization
	4 Single Objective Topology Optimization
	5 Multi-Objective Topology Optimization of Frame Structures
	6 Summary
	References
Parametrization of Cross-Sections by CNN Classification and Moments of Area Regression for Frame Structures
	Abstract.
	1 Introduction
	2 State of the Art
	3 Hierarchical Classification and Regression of Cross-Sections
	4 Case Study on Classification and Regression
	5 Summary
	References
Clustering Topologically-Optimized Designs Based on Structural Deformation
	1 Introduction
	2 Method
	3 Dataset Generation
		3.1 Labeled Test Dataset
		3.2 Topology Optimization Design Dataset
	4 Results and Analysis
		4.1 Results on Labeled Test Dataset
		4.2 Results on to Design Dataset
	5 Conclusion and Future Work
	References
Optimization of Fused Filament Fabricated Infill Patterns for Sandwich Structures in a Three-Point Bending Test
	Abstract.
	1 Infill Structures in Additive Manufacturing
	2 Load-Case-Oriented Infill Patterns
		2.1 Design and Fabrication
		2.2 Experimental Procedure
		2.3 Evaluation
		2.4 Finite Element Analysis
	3 Results and Discussion
	4 Summary and Outlook
	References
Topology Optimization and Production of a UAV Engine Mount Using Various Additive Manufacturing Processes
	1 Introduction
		1.1 Goal
	2 Conceptual Design of the Engine Mount
		2.1 Requirements
		2.2 Previous Situation
		2.3 Load Assumptions and Materials
		2.4 Types of Connections
	3 Topology Optimization of the Engine Mount
		3.1 Design Space
		3.2 Optimization
	4 Manufacturing of the Engine Mount
	5 Testing
	6 Results
		6.1 Optimization Quality
		6.2 Comparison of the Measurements with the Simulation
	7 Conclusion
	References
Multiparametric Design Optimisation of 3D Printed Aircraft Door Seals
	1 Introduction
	2 Overview on the Investigated AM Materials
		2.1 3D Printing Materials and Processes
		2.2 Uniaxial Loading
	3 Mechanical Behaviour of Silicone
		3.1 Hyperelastic Incompressible Models
		3.2 Parameter Identification
		3.3 Model Stability Limitations
	4 Seal Designing Optimisation
		4.1 Optimisation Tasks
		4.2 Multi-objective Search with NSGA-II
		4.3 Optimisation Results
	5 Summary and Conclusion
	6 Appendix
	References
Development, Industrialization and Qualification of a Lever-Shaft-Integration for a Long Range Aircraft
	Abstract.
	1 Preface
	2 Introduction
	3 Requirements of the Door Latch and Design Considerations
	4 Mechanical System and Sizing Operation
	5 Multi-Process Optimization
	6 Certification
	7 Achievements
	References
Characterization and Influences of the Load Carrying Capacity of Lightweight Hub Designs of 3D-Printed Gears (16MnCr5, PBF-LB/M-Process)
	Abstract.
	1 Introduction
		1.1 PBF-LB/M Process (LPBF)
		1.2 Gears Manufactured by PBF-LB/M
	2 Lightweight Gear Hub Designs
		2.1 Topologically Optimized Gear Hub Design
		2.2 Bionically Optimized Gear Hub Design
		2.3 Manufactured Gears and Lightweight Hub Designs
	3 Characteristics of Lightweight Gear Hub Designs
		3.1 Density
		3.2 Microstructure
		3.3 Hardness Depth Profiles
	4 Influence of Lightweight Gear Hub Designs on the Load Carrying Capacity
		4.1 Static Load Carrying Capacity
		4.2 Dynamic Load Carrying Capacity—Tooth Root Bending Strength
		4.3 Dynamic Load Carrying Capacity—Surface Durability
	5 Summary and Outlook
	References
3D Material Model for Additive Manufactured Metallic Parts
	Abstract.
	1 Introduction
	2 Material Characterization
		2.1 Tensile Tests
		2.2 Compression Tests
		2.3 Shear Tests
	3 Non-linear Material Model and Failure Criterion
		3.1 Non-linear Material
		3.2 Failure Criterion
	4 Conclusion and Outlook
	References
Structural Optimization in Lightweight Design for SLM Meets Additive Serial Production and Efficient Post-Machining
	Abstract.
	1 Introduction
	2 Challenges
	3 Process Overview
		3.1 Design
		3.2 Additive Manufacturing
		3.3 Post-Machining
	4 Summary and Conclusion
	References
A Unit Cell with Tailorable Negative Thermal Expansion Based On a Bolted Additively Manufactured Auxetic Mechanical Metamaterial Structure: Development and Investigation
	1 Introduction
	2 Design of the Unit Cells
		2.1 Thermal Expansion Mechanism of the Unit Cell
		2.2 Calculation of Thermoelastic Kinematics Caused by Thermal Expansion
		2.3 Design of Experimental Unit Cells
	3 Materials, Manufacturing and Experimental Procedure
		3.1 Materials
		3.2 Manufacturing and Experimental Procedure
	4 Experimental Results and Discussion
		4.1 Test of the Biaxial Thermal Expansion Behavior
		4.2 Test of Stiffness in the Direction of Thermal Expansion
	5 Conclusion
	References
Author Index