Accelerating Additive Process Qualification with Redesigned Hinge Replacements
The U.S. Army's Tank and Automotive Research, Development and Engineering Center (TARDEC) presented ADAPT with a unique challenge: develop a process for creating replacement hinges for the doors of the Mine-Resistant Ambush Protected (MRAP) light tactical vehicles that would not only improve hinge performance but reduce the time to produce and install replacements when hinges eventually failed in the field.
Together with its members and partners, ADAPT used data-driven additive manufacturing (AM) to reproduce and ultimately redesign the hinges.
An ADAPT partnership of Colorado School of Mines, Elementum 3D, Citrine Informatics and Ft. Carson worked with TARDEC and the Air Force Research Laboratory to first replicate and characterize the fatigue performances of the direct replacement parts made using AM. The knowledge gained from that initial phase of the program informed a redesign of the hinge using design for additive principles, which reduced the number of parts in the hinge assembly from six to one and reduced the maximum stress in the hinge joints from 900 MPa to below 90 MPa (an order of magnitude increase in the factor of safety). Then, in the final stage of the program, ADAPT partnered with Professor Albert To at the University of Pittsburgh to optimize the geometry of the designed-for-AM hinges, which reduced their weight by 38% relative to the original hinge assemblies.
This collaborative process took a data-driven approach that showcased the strengths of the ADAPT Consortium. Using preexisting data from other ADAPT projects already in the adapt.citrination platform, the team was able to predict the quality of the replacement part, which was built using a completely new material/printer combination. The result was an 84% accurate prediction of build parameters on the first print, which simply replicated the design of the existing OEM hinge assembly. Then, the group was able to focus on how to create a simpler, lighter hinge, not just a direct replacement.
Continue reading for more program details and outcomes »
ADAPT Presents at TMS
ADAPT students and faculty are presenting the latest Optimize for AdditiveSM research results this week at TMS 2019 in San Antonio, Texas. See the schedule for our six presentations »