Publication detail

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

VAVERKA, O. KOUTNÝ, D. PALOUŠEK, D.

Original Title

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

English Title

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

Type

journal article in Web of Science

Language

en

Original Abstract

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.

English abstract

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.

Keywords

Axle carrier, Selective Laser Melting, Topology optimization, AlSi10Mg, Formula Student

Released

14.10.2019

Publisher

Emerald Publishing Limited

Location

Bingley, United Kingdom

Pages from

1545

Pages to

1551

Pages count

7

URL

Documents

BibTex


@article{BUT159015,
  author="Ondřej {Vaverka} and Daniel {Koutný} and David {Paloušek}",
  title="Topologically optimized axle carrier for Formula Student produced by selective laser melting",
  annote="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. 
",
  address="Emerald Publishing Limited",
  chapter="159015",
  doi="10.1108/RPJ-07-2018-0171",
  howpublished="online",
  institution="Emerald Publishing Limited",
  number="9",
  volume="25",
  year="2019",
  month="october",
  pages="1545--1551",
  publisher="Emerald Publishing Limited",
  type="journal article in Web of Science"
}