Lightweight design

Lightweight design, in the opinion of Leichtwerk AG, is not just about aircraft design. It also presents a particular challenge as regards developing general mechanical engineering products which are subject to specific requirements of weight, rigidity or dynamic strain.

 

Lightweight design is as important for the wind energy industry as it is for transport technology. Leichtwerk AG combines its engineering expertise with products whose dimensions and weight differ by several orders of magnitude.

Fiber reinforced structures

Automobile structures

 

Cabriolets often have a lower torsional stiffness than cars with a closed body design. So-called x-braces are installed in the undercarriage for additional support. The use of CFRPs (carbon-fiber reinforced plastics) and optimization of component geometry have enabled reductions of the overall mass from around 70kg, in the preliminary draft made from metal, to less than 20kg.

 

Rail structures

 

The construction and engineering specifications of the front part of high-speed trains can present significant challenges. Keeping construction costs low is an important factor, yet at the very fore are issues such as the integration of metal elements (e.g. front hatch hinges and their operation), fire protection requirements, and recurring operational stress and strain factors.

Metallic structures

HEG piston box

 

The piston box records the HEG piston box performance data. The aim behind the design of a new piston box is to create additional impoundment volume by reducing the mass from 37.5kg to 24kg.

Due to the strong dynamic operational stresses and strains, transient FE computations were occasionally used as proof of structural integrity.

Tunnelsimulation

 

Aerodynamic experiments on moving trains, particularly when they are passing through tunnels, are difficult to realize in conventional wind tunnels.

Leichtwerk AG therefore designed a tunnel simulation facility for the DLR in Göttingen.