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    26 views13 pages

    A. Szabo Et Al. 2019 - Adapting Smart Dynamic Casting To Thin Folded Goemetries PDF

    Uploaded by

    Manu K Mohan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Adapting Smart Dynamic Casting to Thin Folded Geometries Anna Szabo", Lex Reiter’, Ena Lloret-Fritschi'”, Fabio Gramazio!, Matthias Kobler', and Robert J. Flat” Gramazio Kohler Research, NCCR Digital Fabrication, ETH Zurich, Zatich, Switzerland szabogarch. eth. ch 2 Institute for Building Materials, NCCR Digital Fabrication, ETH Zurich, Zurich, Switedand Abstract. The fist thin folded concrete prototypes produced with Smart Dynainic Casting (SDC) exposed numerous challenges concerning concrete ‘The SDC process is modelled to explain the inereased difieulty to fabrieate thin folded members compared to columns. Due to the smaller volume to surface ratio in forinworks for thin folded stuctures the effect of rcton is amplified and the process window narrows down. In order to compensate for this, retarted self-compacting mortar mix designs and acceleration strategies are investigated. ‘Material testing results provide guidelines of how to achieve a uniform hardening rate over the course of an experiment, while preserving sufficient ‘uidty and dealing with variations in saw materials. For this, offine pe ‘esoineter tests are performed to evaluate material properties and oaline mei surements are recorded to follow the strength evolution of the same mix processed with the experimental setup. In addition, the slipping eiteion and the deformability of the concrete aze tested in a 1:1 seale robotic experiment to evaluate the fabrication feasibility with the adapted mix. This unveils the potential to produce thin folded members for architectural applications Keywords: Smart Dynamic Casting » Folded structures» Process window 1 Introduction At the age of “the third industrial revolution” [1], mass customization offers a solution fon the quest for expanding design freedom with digital fabrication technologies by translating computer aided design data to manufacturing information in order to control the fabrication process [2]. In digital fabrication, conerete has attracted attention later than other materials, especially due to the difficulty of controlling the fluid to solid transition [3]. This paper focuses on adapting the material mix formulation and the manufacturing protocol of an existing digital fabrication process, Smart Dynamic Casting (SDC) [4] to thin folded geometries. It offers an approach to assess how precisely material parameters have to be in line with the process boundaries, given the geometry © RILEM 2019 T. Wangler and R. J. Flatt (Bas): DC 2018, RILEM Bookseries 19, pp. 81-93, 2010 btpsfdo.org/0,1007/978-3-319.99519.9.8 82 A, Szabo et al SDC is a robotic slipforming process that enables to produce non-standard geometries using a single formwork significantly smaller than the structures produced, by shaping concrete in the delicate phase when it changes fom a yield stress fluid to a ‘cohesive frictional material [5]. In order to perform successful experiments with SDC, it is essential to control the evolution of concrete yield stress in the early hydration phase and synchronize it with the movement of the formwork [6]. SDC is a gravity driven extrusion process in which the concrete weight in the formwork drives the extrusion, while the friction on the sliding formwork walls opposes it [4]. For the process, the cumulative of the spatially variable shear stress along the formwork surface is responsible for friction [7] (Fig. 1). This depends on ‘many parameters, such as formwork material, material evolution, surface geometry and process rate. The ratio of formwork volume to surface is an important parameter and it will be referred to as hydrodynamic radius in this paper. For geometries with small hydrodynamic radius (thus large surface) friction is affecting the process more in relative terms, This relation is taken info account in the model described in the fole Towing section, > ttn gnc an 2 Ts i al 1 oll lt 1 Tada T 1 tpt THT . Fig. 1. Force balance for SDC columns, mullions and thin folded structures Hydrodynamic radi: ry, = suse Examples of previous stdies using SDC: Columns: ry = 2825, with a = b= 150mm => ny = 75mm, Mallions: ry = 224, with a= 100mm, = 70mm = ry = 41 mm Folded structures! ny = 222! = 1, with ¢ = 25mm = ry = 25mm In addition, SDC has three main requirements for the material mix. Firstly, a concrete batch is prepared in a way to provide a long open time ~ the retarded concrete = that ean be activated on demand with an accelerator. Secondly, the retarded material thas to be suitable for pumping. Thirdly, the accelerated material has to be self compacting and duid enough to fill the formwork, not segregate and harden at a known rate [7] ‘The geometrical design space of the process is explored by moving a formwork for thin folded structures along spatial trajectories with a 6-axis robotic arm. The explo- ration follows empirical methodology in which the fabrication feasibility is evaluated Adapting s art Dynamic Cesting to Thin Folded Geometries 83, through physical experimentation at 1:1 scale, For the first experiments, a rigid formwork system for thin folded structures with 90° fold opening is slipped along trajectories in plane with one of its sides. These experiments enhance the understanding of the difficulties due to the smaller process window and serve as the first step towards exploring the architectural potential of thin, folded conerete members with non- standard geometries enabled by the SDC prefabrication process. 2. Slipforming Process Model ‘The force balance between the hydrostatic pressure pif of concrete in the formwork and the cumulated friction of eonerete along. the formwork allows for calculating the vertical stress eye a the extrusion point af , eve = pot > [ emlete w Previously defined failure criteria limit the vertical stress allowed by the slip- forming process to positive values (no cracking caused by tensile stresses) and values Jower than twice the yield stress to atthe time of extrusion fw, (n0 flow according to Tresea criterion) [79 0

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