Light-Weighting of Additive Manufactured Automotive Fixtures through Topology Optimization Techniques

Naik, Abhijith; Sujan, T; Desai, Suraj; Shanmugam, Saravanakumar

doi:10.4271/2019-28-2544

Cited by 3 publications

(1 citation statement)

References 3 publications

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“…Bikas, Dalpadulo et al, Vaverka et al [13][14][15][16][17] redesigned the wheel knuckles of formula race cars through topology optimization and considered laser powder bed fusion (LPBF). The redesign of a gearbox housing and automotive fixtures is seen in Barreiro et al [18] and Naik et al [19] respectively. For works focused on engines, Marchesi et al [20] redesigned a diesel engine support while Barbieri et al [21,22] proposed that steel pistons could be used in place of their aluminum counterparts if they are "lightweighted" through topology optimization.…”

Section: Design For Additive Manufacturingmentioning

confidence: 99%

Structural Design Strategies for the Production of Internal Combustion Engine Components by Additive Manufacturing: A Case Study of a Connecting Rod

Ibhadode¹

2023

Renewable Energy - Recent Advances

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Topology optimization and lattice design strategies are excellent tools within the design for additive manufacturing (DfAM) workflow as they generate structurally optimal, lightweight, and complex features often difficult to produce by conventional manufacturing methods. Moreover, topology optimization approaches are quickly evolving to accommodate AM-related processes and geometric constraints. In this study, the re-design of the connecting rod of an internal combustion engine (ICE) is explored by topology optimization and lattice structures. In both topology optimization and lattice design, the objective is to maximize their structural performances while constraining material usage. Structural analyses are carried out on the optimized topologies to compare their mechanical performances with a benchmark design. Results show that the redesign of the connecting rod through topology optimization alone can realize 20% material savings with only a 5% reduction in the factor of safety. However, the combination of topology optimization and lattice structure design can result in over 50% material savings with a 21–26% reduction in the factor of safety. For manufacturability, the fast-predictive inherent strain model shows the designs through topology optimization and lattice design gives the lowest process-induced deformations before and after support structure removal.

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