Dynamic Modal Correlation of an Automotive Rear Subframe, with Particular Reference to the Modelling of Welded Joints

Rotondella, Vincenzo; Merulla, Andrea; Baldini, Andrea; Mantovani, S.

doi:10.1155/2017/8572674

Cited by 12 publications

(9 citation statements)

References 8 publications

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“…Further dynamic modal analyses are planned to ascertain that the new upright does not significantly affect the noise, vibration and harshness map of the vehicle (see Azadi et al 55 and Rotondella et al 56 ). Further validation tests will be performed on the prototypes presented above, to measure the displacements at the crucial points of the uprights.…”

Section: Resultsmentioning

confidence: 99%

Synergy between topology optimization and additive manufacturing in the automotive field

Mantovani

Barbieri

Giacopini

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article purposes on developing and on re-interpreting the numerical results of a topology optimization for a structural component built via additive manufacturing. A critical appraisal of the optimization results is presented by modeling the feasible component with a holistic approach that merges structural and manufacturing requirements. The procedure is expected to provide a design guideline for similar applications of practical relevance, toward an increase of the right-first-time parts that is required to bring additive manufacturing to its full competitiveness. Topology optimization of a steering upright for a Formula SAE racing car was performed by targeting weight minimization while complying with severe structural constraints, like global and local stiffness performance. Cornering, bumping and braking vehicle conditions were considered. The optimization constraints were evaluated via finite element analysis on a reference component, where the loading conditions were retrieved from telemetry data. The reference part was manufactured by computer numerical control machining from a solid aluminum block. Spurred by the interpretation of the topology optimization predictions, a new upright geometry was designed and validated by calculating its stress field and the possible occurrence of Euler buckling. The new upright was 9% lighter than the reference component. The new geometry was analyzed according to Design for Additive Manufacturing principles to choose the orientation on the build platform and the supports’ location and geometry. The part was successfully manufactured and proved consistent with the application.

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Section: Resultsmentioning

confidence: 99%

Synergy between topology optimization and additive manufacturing in the automotive field

Mantovani

Barbieri

Giacopini

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

Self Cite

View full text Add to dashboard Cite

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“…These constraints impose that modal frequencies are higher, and displacements lower, compared to given thresholds f k and d j , respectively. In particular, the constraints on natural frequencies are adopted to preliminary take into account the NVH response of the assembly and considering the modal alignment chart for our reference vehicle, as shown in Ko et al, 12 Kulkarni and Thyagarajan, 16 and Cavazzuti et al 43 Nevertheless, further analysis on frequency response of the structure should be carried out a posteriori, see Rotondella et al 49 As an alternative, the dynamic response of the structure under dynamic excitations might be investigated as presented in Kang et al 50 and Zhang and Kang. 51 Finally, the thresholds derive from results obtained for the reference dash, as shown in Table 1.…”

Section: Mathematical Formulation Of Optimization Problemmentioning

confidence: 99%

Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints

Mantovani

Campo

Ferrari

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is in the front area of the Body-in-White, between the left-hand-side shock-tower and the Cross Car Beam, and its task is to support the steering column. The dash under investigation is an asymmetric rib-web aluminium casting part. The influence of Additive Manufacturing constraints together with modal and stiffness targets is investigated in view of mass reduction. The constraints drive the topology result towards a feasible and fully self-supporting Additive Manufacturing solution. A simplified finite element model of the steering column and of the Body-in-White front area is presented, and the limiting assumption of isotropic material for Additive Manufacturing is discussed. The optimization problem is solved with a gradient-based method relying on the Solid Isotropic Material with Penalization and on the RAtional Material with Penalization algorithms, considering the overhang angle constraint with given build directions. Three metals are tested: steel, aluminium and magnesium alloys. Topology optimization results with and without overhang angle constraints are discussed and compared. The aluminium solution, preferred for its lesser weight, has been preliminarily redesigned following the optimization results. The new dash concept has been validated by finite element considering stiffness, modal responses, and buckling resistance targets. The proposed dash design weighs 721 g compared to the 1537 g of the reference dash, with a weight reduction of 53%, for the same structural targets.

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“…According to the guidelines described in [43][44][45], CAD systems represent state-of-the-art tools for lowering the accessibility level and enhancing KBE in industry. Again, the development of the CAD-based approach to machine design has proven to be effective in many industrial fields for the analysis and simulation of complex machines [46][47][48][49][50][51][52]. Therefore, a DA can integrate parametric CAD modeling in order to support the selection and design of a machine subsystem.…”

Section: Computer-aided Design Archetype Toolmentioning

confidence: 99%

The Systematic Design of Industrial Products through Design Archetypes: An Application on Mechanical Transmissions

2020

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Engineering design is a knowledge intensive activity for both new and mature technical systems, such as mechanical transmissions. However, design knowledge is often transferred with conservative and unstructured approaches, although knowledge management would be of the utmost importance for modern industries. In this work, we introduce a design tool, called design archetype, for collecting and managing knowledge in systematic design processes. The design archetype addresses input design requirements for different design concepts, therefore, improving awareness of the design process by interactively modifying the design solution due to different input requirements. Finally, the design archetype updates the parameters of a first embodiment computer-aided design model of the concept. A method for the development of design archetypes is presented and applied to two case studies of mechanical transmission subassemblies. The results demonstrate the effectiveness of a systematic design method based on design archetypes stored in the company database.

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Dynamic Modal Correlation of an Automotive Rear Subframe, with Particular Reference to the Modelling of Welded Joints

Cited by 12 publications

References 8 publications

Synergy between topology optimization and additive manufacturing in the automotive field

Synergy between topology optimization and additive manufacturing in the automotive field

Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints

The Systematic Design of Industrial Products through Design Archetypes: An Application on Mechanical Transmissions

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