01.09.2020
Author: Rodenbücher Julia, Marketing, toolcraft AG, Georgensgmünd
toolcraft AG is a pioneer in forward-looking technologies such as 3D printing in metal and the construction of individual turn-key robot solutions. In engineering, it tests innovative processes and makes them ready for series production.
Description of the component:
The project of Deutsche Bahn and toolcraft AG deals with the production of an assembly consisting of nine innovative turbine segments, which are assembled into a turbine wheel using a carrier ring. This component was manufactured using metallic 3D printing and is a component in an alternator that generates electricity using steam.
Challenges:
The challenge and goal was to achieve an easily detachable connection between the turbine segments. A high turbine performance and the design for a high dynamic load had to be guaranteed, and the ambient temperature and surface roughness had to be taken into account. A rotationally symmetrical design was also required to avoid imbalance. Another aim of the project was to reduce costs.
Solution:
The aforementioned requirements could be met by redesigning the turbine blade segments to optimize the flow. This means that fewer support structures are required and the amount of reworking has also been reduced. The benefits include innovative and AM-compliant spare parts management and an increase in turbine performance. As a result, costs and assembly work can be significantly reduced. Companies dealing with the spare parts management of the future will benefit from this innovation. AM-compliant design and redesign offer great potential, on the one hand through added value in the component or assembly itself, but also in terms of availability on demand.
Conclusion:
The project impressively demonstrates the potential of additive manufacturing in spare parts management. Simply "reprinting" the components would not have produced anywhere near such optimizations. It is therefore worth taking a close look at the technology and the associated opportunities and benefits.