Topologically optimized axle carrier for Formula Student produced by selective laser melting

Result code in IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F00216305%3A26210%2F19%3APU133510" target="_blank" >RIV/00216305:26210/19:PU133510 - isvavai.cz</a>

Result on the web

<a href="https://www.emerald.com/insight/content/doi/10.1108/RPJ-07-2018-0171/full/html" target="_blank" >https://www.emerald.com/insight/content/doi/10.1108/RPJ-07-2018-0171/full/html</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.1108/RPJ-07-2018-0171" target="_blank" >10.1108/RPJ-07-2018-0171</a>

Result language

angličtina

Original language name

Topologically optimized axle carrier for Formula Student produced by selective laser melting

Original language description

Purpose – This paper aims to present the design process, manufacturing and testing of a prototype of an axle carrier for Formula Student race car. The axle carrier is topologically optimized and additively manufactured using Selective Laser Melting (SLM). Design/Methodology/Approach –The shape of axle carrier was created in 3 design stages using topology optimization and 4 additional design stages based on finite element calculations and experimental testing. The topology optimization was performed on the basis of relevant load cases. The 6th design stage was manufactured by SLM and then tested on a loading device together with photogrammetry measurement to obtain the real deformation. Measured deformations were compared with deformation calculated by FEM, verified and experiences used in the last design stage. Findings – Additively manufactured axle carrier has minimal safety factor 1.2 according to experimental testing. The weight and maximal deformations are comparable with the milled part, although the material has about 50% worse yield strength. The topologically optimized axle carrier proved big potential in effective distribution of material and improvement of toughness. Practical Implications – It helps Formula Student team to enhance the driving performance while keeping low weight. It also improves further development and upgrading of the race car. Originality/Value – The whole design of the topologically optimized part was investigated. From estimating the loads to experimental verification of FEM analysis on real part.

Czech name

—

Czech description

—

Type

J_imp - Article in a specialist periodical, which is included in the Web of Science database

CEP classification

—

OECD FORD branch

20301 - Mechanical engineering

Project

<a href="/en/project/ED0002%2F01%2F01" target="_blank" >ED0002/01/01: NETME Centre (New Technologies for Mechanical Engineering)</a><br>

Continuities

P - Projekt vyzkumu a vyvoje financovany z verejnych zdroju (s odkazem do CEP)<br>S - Specificky vyzkum na vysokych skolach

Publication year

2019

Confidentiality

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Name of the periodical

RAPID PROTOTYPING JOURNAL

ISSN

1355-2546

e-ISSN

1758-7670

Volume of the periodical

25

Issue of the periodical within the volume

9

Country of publishing house

GB - UNITED KINGDOM

Number of pages

7

Pages from-to

1545-1551

UT code for WoS article

000490748700010

EID of the result in the Scopus database

2-s2.0-85073627037