Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank

Abstract

This paper describes a new design method that was developed to achieve an optimal design method for weight reduction of a bell crank, sourced from a Louis Christen Road Racing F1 Sidecar. The method involved reverse engineering to produce a 3D model of the mechanical part. The 3D bell crank model was converted to a finite element (FE) model to characterize the eigenvalues of vibration and responses to excitation using the Lanczos iteration method in Abaqus software. The bell crank part was also tested using a laser vibrometer to capture its natural frequencies and corresponding vibration mode shapes. The test results were used to validate the FE model, which was then analysed through a topology optimization process. The objective function was the weight and the optimization constraints were the stiffness and the strain energy of the structure. The optimized design was converted back to a 3D model and then fabricated to produce a physical prototype for design verification and validation by means of FE analysis and laboratory experiments and then compared with the original part. Results indicated that weight reduction was achieved while also increasing the natural frequency by 2%, reducing the maximum principal strain and maximum von Mises stress by 4% and 16.5%, respectively, for the optimized design when compared with the original design. The results showed that the proposed method is applicable and effective in topology optimization to obtain a lightweight (~3% weight saving) and structurally strong design.

Topology Optimization of a Bell Crank Lever Based on Stiffness and Mass using Finite Element Analysis

“…A. M. Sharma et al [4] crank is used in student formula prototypes which was subjected to a Pullrod force of 1650N , a Damper force of 24N and a Fulcrum force 1674N.Their initial design's stress and deformation was 143.09 MPa and 0.038mm while the final design had a stress generation of 491.65MPa and got deformed by 0.117mm.The material was also shifted from Aluminium 7075 T6 to Titanium 6Al-4V Grade 5 which resulted in weight reduction by 54%. A. Pande et al [3] showed that there is a 55.92% weight reduction in the crank but the displacement varied from 0.0024 to 0.0021 mm only and the stress changed from 0.018MPa to 0.02 MPa.. T. Y. Pang et al [5] had their crank subjected to 2609N in Y direction and 460N in X direction. The original and optimized crank stress values varied from 239.3MPa to 199.8 MPa whereas mass increased by 2.6%.…”

“…Abhishek Mahesh Sharma et al [4] focused on determining bell crank dimensions followed by static structural analysis and optimization of Formula Student Bell Crank along with change in material from Aluminium 7075 to Titanium 6Al-4V Grade 5. T. Y. Pang et al [5] concentrated on the reverse engineering of bell crank on the basis of its natural frequency. They validated their FEA modal analysis experimentally using a laser vibrometer, manufactured their crank, and assembled it in their vehicle.…”

“…It refers to a method wherein optimum material is removed when subjected to boundary conditions of mass, stiffness and material [16]. The method helps achieving conclusive designs with lowered material costs and weight without compromising the structural integrity of the component [3,5]. Usually, the designs obtained from the software are not feasible for further processes.…”

Lightweight Design and Analysis of Steering Knuckle of Formula Student Car Using Topology Optimization Method

“…The car's suspension system plays a crucial role in ensuring ride comfort, steering stability, and optimal wheel motion characteristics, particularly when encountering changing road conditions or varying loads. In the context of TO, Pang and Toh Yen [6] proposed an upgraded design for LW racing arms, while Bin ab Razak et al [7] explored the application of TO in the development of additional lightweight racing cars. These studies contribute to the advancement of lightweight design and optimization techniques for racing vehicles, ultimately improving their overall performance and efficiency.…”

Topology Optimization and Fatigue Life Estimation of Sustainable Medical Waste Shredder Blade

“…Therefore, fatigue failure is also considered in this study because it is an important design consideration that ensures the durability of a mechanical structure. Recently, FE-SAFE is increasingly being used to estimate the Although various optimization approaches have been adopted by researchers to obtain optimal geometry of a structural component to reduce system weight and power consumption [10][11][12][13], the literature available on the design aspect of the shredder system is limited and only discusses the static and modal analysis [14][15][16][17][18][19]. Various structural topology optimization methods have been adopted by researchers to improve the material distribution of engineering structures [20][21][22][23].…”