A Design Strategy Based on Topology Optimization Techniques for an Additive Manufactured High Performance Engine Piston

Barbieri, Saverio Giulio; Giacopini, Matteo; Mangeruga, Valerio; Mantovani, S.

doi:10.1016/j.promfg.2017.07.162

Cited by 39 publications

(23 citation statements)

References 17 publications

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“…Additive Manufacturing (AM) introduces an opportunity whereby this theoretically idealised geometry can be manufactured with a greater degree of economic sensibility. TO for AM has therefore become an active research area, utilizing the approach for a number of component performance objectives, such as heat transfer efficiency [10], stiffness [11], and mass [12]. A design produced using this combination of techniques could therefore exhibit maximum stiffness at a minimum mass, achieving ultimate product performance.…”

Section: Introductionmentioning

confidence: 99%

Design & Manufacture of a High-Performance Bicycle Crank by Additive Manufacturing

McEwen

Cooper²,

Warnett

et al. 2018

Applied Sciences

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A new practical workflow for the laser Powder Bed Fusion (PBF) process, incorporating topological design, mechanical simulation, manufacture, and validation by computed tomography is presented, uniquely applied to a consumer product (crank for a high-performance racing bicycle), an approach that is tangible and adoptable by industry. The lightweight crank design was realised using topology optimisation software, developing an optimal design iteratively from a simple primitive within a design space and with the addition of load boundary conditions (obtained from prior biomechanical crank force–angle models) and constraints. Parametric design modification was necessary to meet the Design for Additive Manufacturing (DfAM) considerations for PBF to reduce build time, material usage, and post-processing labour. Static testing proved performance close to current market leaders with the PBF manufactured crank found to be stiffer than the benchmark design (static load deflection of 7.0 ± 0.5 mm c.f. 7.67 mm for a Shimano crank at a competitive mass (155 g vs. 175 g). Dynamic mechanical performance proved inadequate, with failure at 2495 ± 125 cycles; the failure mechanism was consistent in both its form and location. This research is valuable and novel as it demonstrates a complete workflow from design, manufacture, post-treatment, and validation of a highly loaded PBF manufactured consumer component, offering practitioners a validated approach to the application of PBF for components with application outside of the accepted sectors (aerospace, biomedical, autosports, space, and power generation).

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Section: Introductionmentioning

confidence: 99%

Design & Manufacture of a High-Performance Bicycle Crank by Additive Manufacturing

McEwen

Cooper²,

Warnett

et al. 2018

Applied Sciences

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“…This optimized part obtained from topology optimization method and manufactured by Selective Laser Melting (SLM). In the same way isolated motorcycle parts like motorcycle swing arm (Powar et al, 2016), motorcycle front wheel (Joshi et al, 2016) and motorcycle piston (Barbieri et al, 2017) were developed or evolved with the usage of topology optimization techniques and additive manufacturing methods with maximum overall weight reduction between 24 and 44%.…”

Section: Survey On Vehicle Design Optimizationmentioning

confidence: 99%

“…Topology optimization initiates from a bounded material volume, which represents the design space for the process. The adoption of a geometry as simple as possible is very important to achieve a regular high quality mesh (Barbieri et al, 2017). Inside this design space, there are specific areas having important functional and ergonomical characteristics.…”

Section: Introductionmentioning

confidence: 99%

Nested Topology Optimization Methodology for Designing Two-Wheel Chassis

Manios¹,

Lagaros²,

Nassiopoulos³

2019

Front. Built Environ.

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Weight reduction has always been a challenge for the automotive industry, mainly to reduce consumption but also improve handling. In electric vehicle design, the battery packs, their shape and positioning are critical aspects that determine the overall weight, weight distribution and, as a consequence, the efficiency, dynamics and stability of the vehicle. This presented a new challenge, to manage this necessary and inflexible weight and volume, developing the vehicle chassis around it and in the best possible way, without compromising the overall efficiency and behavior. In this work, a methodology for nested topology optimization has been developed which combines structural topology optimization and battery pack shaping and positioning. The new methodology is implemented without limiting its applicability, into the framework of the commercial software Hyperstudy by Altair.

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“…Many studies are engaged in modeling the thermal stress and strain state of a piston (Abramchuk and Avramenko, 2009;Agarwal and Varghese, 2006;Dallwoo et al, 2012;Rahmani et al, 2017;Barbieri et al, 2017;Zhao et al, 2014;Lu et al, 2017;Schreer et al, 2014;Finol and Robinson, 2006). To increase the accuracy and information content of modeling results, they recommend considering groups of parts to account for joint thermomechanical deformation.…”

Section: Introductionmentioning

confidence: 99%

Prospects of Using Steel Pistons in Transport Diesel Engines

Абрамчук

Авраменко

2019

Period. Polytech. Transp. Eng.

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The results of comparative design research in the thermal stress and strain state of the piston in transport diesel engine 2 F 10.5/12 are given for its rated power operation. The standard piston is made of an aluminium alloy, and the modernized one, of steel. Piston thermal profiling and indicator test results were used for identifying the mathematical models and refining the boundary conditions for mechanics and heat conduction problems. To ensure reliable heat rejection from the piston, the paper considered the case of oil jet cooling. This was taken into account when describing the boundary conditions of the heat conduction problem. The thin-wall steel piston with oil jet cooling was shown to function reliably under the study conditions. The temperature in the first compression ring groove does not exceed 200 °С, and the radial deformation of the piston crown is less than half of that of an aluminium alloy standard piston.

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A Design Strategy Based on Topology Optimization Techniques for an Additive Manufactured High Performance Engine Piston

Cited by 39 publications

References 17 publications

Design & Manufacture of a High-Performance Bicycle Crank by Additive Manufacturing

Design & Manufacture of a High-Performance Bicycle Crank by Additive Manufacturing

Nested Topology Optimization Methodology for Designing Two-Wheel Chassis

Prospects of Using Steel Pistons in Transport Diesel Engines

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