Investigation of generative design for powder bed fusion technology in case of Formula Student race car components using Ti6Al4V alloy

Markovits, Tamás; Szederkényi, Bence

doi:10.1016/j.jmapro.2022.05.058

Cited by 7 publications

(3 citation statements)

References 38 publications

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“…al. [2]. In this study the amount of material utilised, the weight of the support, the capability of printing with higher internal stresses, and the minimization of deformations are all taken into consideration.…”

Section: Literature Referencesmentioning

confidence: 99%

Investigation on Generative Designs for Fast Connector Socket (FCS) Using High-Strength Low-Alloy (HSLA) Steel

Narayana,

Reddy,

Reddy

2023

AMM

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This study appears to focus on the application of metal additive manufacturing and generative designs to create more efficient and sustainable metallic components. The methodology developed in this study takes a comprehensive approach, from component selection to validation of outputs, which can lead to more efficient use of metallic parts in the future. Here CATIA V5 R20 used to create three new models of a fast connector socket (FCS) components, and then using ANSYS Workbench 16.0 apply the working load limit of 4.5 ton load with AISI 4142 380 qt steel alloy material used to the models to analysis. The Autodesk Fusion 360 software was then used to create generative designs for the fast connector socket models, which aimed to reduce mass, size, and material of the model while maintaining its effectiveness. The generative design approach used in this study is inspired by nature's evolutionary design process and considers production processes and cost restrictions. This approach can lead to the creation of more efficient and sustainable metallic components that can be used in various applications, including mechanical, marine, mining, construction, load lifting, pulling, and holding. Overall, this study highlights of the potential benefits. The comprehensive methodology used in this study can be applied to other metallic component designs to improve their efficiency and sustainability.

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Section: Literature Referencesmentioning

confidence: 99%

Investigation on Generative Designs for Fast Connector Socket (FCS) Using High-Strength Low-Alloy (HSLA) Steel

Narayana,

Reddy,

Reddy

2023

AMM

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“…This study was an outcome of the collaboration between Additive Manufacturing (AM) laboratory ProtoLab [17] and one of the Czech student racing teams, who participated in an international engineering design competition where student teams from around the world design, build, test and race a small-scale racing car following the rules and requirements [18]. The trend in student teams is to redesign parts of the racing car to minimize the mass and to maximize the stiffness of the construction [19,20]. This study aims to investigate the role of TO and 3D printing in the redesigning process of the existing part, the clutch lever (Figure 1).…”

Section: Introductionmentioning

confidence: 99%

Topology Optimization of the Clutch Lever Manufactured by Additive Manufacturing

et al. 2023

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This article aims to review a redesign approach of a student racing car’s clutch lever component, which was topologically optimized and manufactured by Additive Manufacturing (AM). Finite Element Method (FEM) analysis was conducted before and after a Topology Optimization (TO) process in order to achieve equivalent stiffness and the desired safety factor for the optimized part. The redesigned clutch lever was manufactured by using AM–Selective Laser Melting (SLM) and printed from powdered aluminum alloy AlSi10Mg. The final evaluation of the study deals with the experimental test and comparison of the redesigned clutch lever with the existing part which was used in the previous racing car. Using TO as a main redesign tool and AM brought significant changes to the optimized part, especially the following: reduced mass of the component (10%), increased stiffness, kept safety factor above the 3.0 value and ensured the more aesthetic design and a good surface quality. Moreover, using TO and AM gave the opportunity to consolidate multi-part assembly into a single component manufactured by one manufacturing process that reduced the production time. The experimental results justified the simulation results and proved that even though the applied load was almost 1.5× higher than the assumed one, the maximum von Mises stress on the component was still below the yield limit of 220 MPa.

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“…[5]. Formula one cars use additive manufacturing widely due to manufacturing custom made components and parts [6]. In the field of Aerospace fixtures, rocket nozzles, mounts, etc.…”

Section: Introductionmentioning

confidence: 99%

Experimental Fatigue Studies of Additively Manufactured Fiber Reinforced Thermoplastic

Jason,

Mudakappanavar,

Sreekanth

et al. 2023

jmmf

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Additive manufacturing (AM) is a field of study that is gaining importance due to quick manufacturing techniques while providing viable flexibility in design modifications. In comparison with conventional manufacturing methods, AM uses easier processes to manufacture intricate components. AM products maintain consistency as it is constructed by robust universal AM machines. In the present study, a continuous carbon fiber thermoplastics (CFRTP) as a replacement to aluminum alloy (Al6061-T6) material is used for additively manufacturing bicycle crank components. The results from the tensile test and fatigue behavior of the component indicate a strong dependence of percentage concentration of the reinforcement in the CFRTP. A finite element analysis is performed to ascertain the stress distribution for a static load condition as mimicked in the real world situations. To explore the brittle fracture nature of the CFRTP specimen, a SEM image depicting the microstructural nature is provided. It is imperative to note that the comparative studies indicate the light weight CFRTP crank specimen stands out to be a viable replacement to the Al 6061-T6 material.

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Investigation of generative design for powder bed fusion technology in case of Formula Student race car components using Ti6Al4V alloy

Cited by 7 publications

References 38 publications

Investigation on Generative Designs for Fast Connector Socket (FCS) Using High-Strength Low-Alloy (HSLA) Steel

Investigation on Generative Designs for Fast Connector Socket (FCS) Using High-Strength Low-Alloy (HSLA) Steel

Topology Optimization of the Clutch Lever Manufactured by Additive Manufacturing

Experimental Fatigue Studies of Additively Manufactured Fiber Reinforced Thermoplastic

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