THE STARTING POINT:
OPTIMISED TOPOLOGY REDUCES WEIGHT
With its clear focus on the environment and innovative design, KYBURZ Switzerland AG has become the largest Swiss manufacturer of electric vehicles. Its electric vehicles set the bar for energy efficiency and help reduce drivers’ carbon footprint. But KYBURZ is more than just an electric vehicle manufacturer – its mission is to drive innovation onto the road. Staying true to this mission, its eRod Offroad model comes with 3D-printed steering knuckles. NX software from Siemens Digital Industries Software was used to design the steering knuckle and optimise its topology.
THE SOFTWARE:
SIEMENS NX IN USE AS END-TO-END CAD, CAE AND CAM SOFTWARE
Siemens NX seamlessly integrates CAD and CAE tools. The software can be used to design and run structural simulations on complex components in just one environment. This integration simplifies the design process and reduces the need to translate data between software packages. The generative design features allow lightweight and structurally efficient designs to be produced automatically, reducing the amount of materials used and improving performance characteristics. NX has specialist modules for preparing components for additive manufacturing. These can be used to design and optimise components for 3D printing. CAM can be used to effectively generate tool paths for machining operations. This is indispensable for the post-processing of various components.
THE MANUFACTURING PROCESS:
END-TO-END ADDITIVE MANUFACTURING PROCESS CHAIN
As a pioneer in additive manufacturing, toolcraft took on the task of manufacturing the steering knuckles. The company uses Siemens NX throughout its additive manufacturing process chain. By combining design and process simulation with the creation of building jigs for the machining process, as well as advanced CAM strategies, NX allows the steering knuckles to be manufactured efficiently and precisely. After printing and de-powdering, the steering knuckles are heat treated in a vacuum furnace to optimise their mechanical properties and increase their strength. An innovative, patented ice blasting process is used to ensure that the supporting structures are removed gently and effectively. To inspect the precision of the manufactured parts, toolcraft uses both the GOM measurement system and tactile measurement methods. As the final step, toolcraft carries out technical cleaning to ensure that the components are free from any residues and contamination.
THE RESULT:
SUSTAINABLE COMPONENTS THANKS TO SIEMENS NX
Siemens NX ensures data consistency from the design stage all the way through to the finished component – all in one software environment without any interfaces. This saves time and money, especially when making retrospective design changes. The additively manufactured steering knuckles are lighter, much more dimensionally stable and can withstand higher loads, so they do not just save weight, but energy as well.
