Meccanica Magazine n. 4

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meccanica magazine38ENGBetween nature and engineering: Additive manufacturing enablesefficient components for nautical applicationsDMEC researchers developed a novel solution for producingbiomimetic surface textures - inspired by the European bass - on Alalloycomponents. Project Levrek (Levrek is the Turkish name of theEuropean Bass) aims to mimic the scales of the European bass on arudder bulb designed for the sailing boat for the Polimi Sailing Team.The objective of the project is to improve the structural features ofthe component, reducing its weight using additive manufacturing(AM) technique, taking the chance also to improve the fluid-dynamicfeatures by texturing its surface.The researchers modelled the natural features of the fish in a digitalenvironment, carried out a parametric analysis with computationalfluid dynamics (CFD) approach to assess its performance andchoose the most efficient scale proportions.After undergoing a topology optimization phase and being producedby laser powder bed fusion, a layer-by-layer additive manufacturing(AM) technique, the designed metallic scales were applied on a rudderbulb. These research activities perfectly meets the objectives of theDepartments of Excellence in the LIS4.0 project, where the focus ison Lightweight and Smart structures.The research required a multidisciplinary team composed bySailing, CFD and AM experts. Alessandro Scarpellini, the leader ofPolimi Sailing Team worked together with Dr. Paolo Schito and Prof.Ali Gökhan Demir. For the innovative design, a first study on thehydrodynamics of European Bass scales was conducted, identifyingthe most promising scale dimension that reduces the rudder bulbfluid-dynamic resistance. The researchers modelled the fish scalesin a 3D computer aided design environment first.Different scale dimensions were tested using CFD within theopensource framework OpenFOAM on the High-PerformanceComputer (HPC) infrastructure CFDHub: the researchers discoveredthe most suitable dimensions as well as the influence of surfaceroughness and the sail speed. Then the focus was on the realizationof the component: laser powder bed fusion was chosen as metaladditive manufacturing process and the material is AlSi7Mg0.6 alloy.The rudder bulb was then topologically optimized to reduce theweight of the component. The chosen fish scale was integrated tothe surface of the bulb. Finally, the component was produced by aTrumpf TruPrint 3000 at AddMe.Lab. The produced rudder bulb isone of the first of its kind incorporating bioinspired surfaces andtopological optimization in a metallic component.For the naval applications, the novel findings can open newpossibilities for improving the sailing performance, but also forreducing material usage. The initial findings of the research hasbeen peer-reviewed and published. The innovativeness of the workhas also been appreciated by the industry as Alessandro Scarpelliniwas awarded the UCIMU Thesis Prize by the Italian Machine Tool,Robots, Automation Systems and Ancillary Products Manufacturers’Association.
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Meccanica Magazine n. 4

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