![]() This temperature drop allowed the use of aluminum as the material for the generator housing. The maximum temperature was reduced by 33%, while the external temperature of the generator dropped by 86% and down to 27☌, making it safe to the touch. The results showed a dramatic reduction in the part’s operating temperature. They combined results from thermal FE analysis carried out in nTopology with CFD simulations in Ansys Fluent. The team evaluated the effect of the conformal cooling channels on the performance of the system through simulations. Thermal analysis results of the microturbine generator housing carried out in nTopology. It also opened up opportunities to add additional functionality: conformal cooling channels for heat management. The entire process required only a few simple design blocks in nTopology, was performed almost instantaneously without errors and took less than a day’s work before the part was ready to manufacture. Finally, they smoothed the internal geometry to ensure that it required no support structures during manufacturing with VELO3D’s metal AM process.Then they removed unnecessary material to create a hollow shell with a variable wall thickness.They first confirmed that the loads on the housing were relatively small using nTopology’s integrated static and modal analysis simulation tools.To achieve these results, Enriquez’s team followed a Field-Driven Design approach: Redesigning the part for Additive Manufacturing was a straightforward process. ![]() This way, part consolidation is an essential technique for improving machine reliability. Having multiple parts in an assembly increases the chances of misalignment. ![]() When the engine spins at 90,000 rpm, everything needs to be precisely aligned. It features a conformal cooling channel created using variable shelling and automated smoothening.Īs a bonus, the originally CNC machined housing can now be manufactured in a single piece with metal Additive Manufacturing. The redesigned microturbine generator housing. ![]() The engineers of KW Micro Power, nTopology, and VELO3D created a housing that is not only much lighter than the original design and manufacturable as one piece with minimal support structures but also features internal conformal channels for cooling the engine and preheating the fuel. In this case study, we document the design of a critical component of KW Micro Power’s airborne microturbine: the generator housing. “I think this is like the renaissance of engineering,” he mentions. But he is astonished by the capabilities of contemporary design software and additive manufacturing systems. Over his long and successful career, he has led engineering teams in Rolls-Royce, worked with DARPA on the first Micro Air Vehicle (MAV) VTOL drone microturbine propulsion systems, and bought the second 3D printing system ever manufactured by Stratasys. Over the past five years, Enrique Enriquez, the president of KW Micro Power, has worked tirelessly to create a microturbine generator roughly the size of a microwave oven that can crank out more power than systems ten times as large.Įnriquez is no stranger to aerospace design and manufacturing. They are a small Florida-based manufacturer looking for new, cutting-edge solutions. txt file is free by clicking on the export iconĬite as source (bibliography): Powers of 10 on dCode.KW Micro Power designs and manufactures high power density Auxiliary Power Units (APUs) for commercial aviation and military applications. The copy-paste of the page "Powers of 10" or any of its results, is allowed as long as you cite dCode!Įxporting results as a. ![]() Except explicit open source licence (indicated Creative Commons / free), the "Powers of 10" algorithm, the applet or snippet (converter, solver, encryption / decryption, encoding / decoding, ciphering / deciphering, translator), or the "Powers of 10" functions (calculate, convert, solve, decrypt / encrypt, decipher / cipher, decode / encode, translate) written in any informatic language (Python, Java, PHP, C#, Javascript, Matlab, etc.) and all data download, script, or API access for "Powers of 10" are not public, same for offline use on PC, mobile, tablet, iPhone or Android app! Ask a new question Source codeĭCode retains ownership of the "Powers of 10" source code. It is the International Committee for Weights and Measures that defined the international unit system, the latest changes took place in November 2022. The table of prefixes for powers of 10 from the International System of Unit (ISU) is:. ![]()
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