Topological Optimization of Brake Pedal for Metal Additive Manufacturing: A Case Study

محورهای موضوعی : additive manufacturing

Batuhan Izgi ¹ , Meltem Eryildiz ² , Mirigül Altan ³

1 - Department of Mechanical Engineering, Yildiz Technical University, Istanbul, Turkey
2 - Department of Mechanical Engineering, Faculty of Engineering and Architecture, Beykent University, Istanbul, Turkey
3 - Department of Mechanical Engineering, Yildiz Technical University, Istanbul, Turkey

تاریخ دریافت : 1400/02/29 تاریخ پذیرش : 1400/03/27 تاریخ انتشار : 1400/03/11

کلید واژه: Additive Manufacturing, analysis, Light Weight, Topological Optimization,

چکیده مقاله :

Additive Manufacturing (AM) has become popular for rapid prototyping and it is presently widely used in different branches of industry because of its advantages such as freedom of design, mass customization, waste minimization and the ability to manufacture complex shape. AM is the process of making 3D object from computer model data by depositing of material layer by layer. Topology optimization is iterative modifying the shape and optimizing material within a given designs space for load, boundary condition thus leading to weight reduction of components. Thus, to form lightweight components which have great advantage where energy consumption is minimal, topology optimization is used. Reducing weight and decreasing the material usage while keeping the product functions are the main challenges. Studies on the integration of the topology optimization and additive manufacturing, specifically mass reduction attract considerable attention. The topology optimization process is employed in this case study, to redesign a lightweight automotive brake pedal to show the potential of topology optimized design for additive manufacturing. As a result of this study 54.07% weight reduction was achieved in the total mass. The thermo- mechanical analysis for additive manufacturing showed that the part without topological optimization 108 MPa of stress and 1,099 mm of displacement were obtained and after optimization they were 196,1 MPa and 1,295 mm, respectively.

منابع و مأخذ:

[1]     Gajdos, I., Slota, J., Influence of Printing Conditions on Structure in FDM Prototypes, Technical Gazette, Vol. 20, 2013, pp. 231-236.

[2]     Ngo, T. D., Kashani, A., Imbalzano, G., Nguyen, K.T.Q., and Hui, D., Additive Manufacturing (3D printing): A Review of Materials, Methods, Applications and Challenges, Composites Part B: Engineering, Vol. 143, 2018, pp. 172-196, DOI. 10.1016/j.compositesb.2018.02.012.

[3]     Alafaghani, A., Qattawi, A., and Ablat, M. A., Design Consideration for Additive Manufacturing: Fused Deposition Modelling. Open Journal of Applied Sciences, Vol. 7, 2017, 291-318, DOI.10.4236/ojapps.2017.76024.

[4]     Nirish, M., Rajendra, R., Suitability of Metal Additive Manufacturing Processes for Part Topology Optimization – A Comparative Study, Materials Today: Proceedings, Vol. 27, 2020, pp. 1601-1607, DOI. 10.1016/j.matpr.2020.03.275.

[5]     Xu, Y., Wu, X., Guo, X., Kong, B., Zhang, M., Qian, X., Mi, S., and Sun, W., The Boom in 3D-Printed Sensor Technology, Sensors, Vol. 17, 2017, 1166, DOI. 10.3390/s17051166

[6]     Gebisa, A. W., Lemu, H. G., A Case Study On Topology Optimized Design for Additive Manufacturing, IOP Conf. Ser.: Mater. Sci. Eng., Vol. 276, 2017, 012026, DOI. 10.1088/1757-899X/276/1/012026.

[7]     Zhu, Z., Zhou, H., Wang, C., Zhou, L., Yuan, S., and Zhang, W., A Review of Topology Optimization for Additive Manufacturing: Status and Challenges, Chinese Journal of Aeronautics, Vol. 34, 2021, pp. 91-110, DOI. 10.1016/j.cja.2020.09.020.

[8]     Munteanu, S., Munteanu, D., Gheorghiu, B., Bedo, T., Gabor, C., Cremascoli, P., Alemani, F., and Pop, M. A., Additively Manufactured Femoral Stem Topology Optimization: Case Study, Materials Today: Proceedings, Vol. 19, 2019, pp. 1019-1025, DOI. 10.1016/j.matpr.2019.08.016.

[9]     Orme, M., Madera, I., Gschweitl, M., and Ferrari, M., Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware, Designs, Vol. 2, No. 51, 2018, pp. 1-22. DOI. 10.3390/designs2040051

[10]  Amir M. Mirzendehdel, Krishnan Suresh, Support Structure Constrained Topology Optimization for Additive Manufacturing, Computer-Aided Design, Vol. 81, 2016, pp. 1-13, DOI. 10.1016/j.cad.2016.08.006.

[11]  Brackett, D., Ashcroft, I., Hague, R. Topology Optimization for Additive Manufacturing, 22nd Annual International Solid Freeform Fabrication Symposium, An Additive Manufacturing Conference, Texas, 2011, pp. 348–362.

[12]  Leary, M, Merli, L., Torti, F., Mazur, M., and Brandt, M., Optimal Topology for Additive Manufacture: A Method for Enabling Additive Manufacture of Support-Free Optimal Structures, Materials & Design, Vol. 63, 2014, pp. 678-690, DOI. 10.1016/j.matdes.2014.06.015.

[13]  Monaheng, L. F., du Preez, W. B., Kotze, N., and Vermeulen, M., Topology Optimisation of an Aircraft Nose-Wheel Fork for Production in Ti6Al4V by the Aeroswift High-Speed Laser Powder Bed Fusion Machine, MATEC Web Conf., Vol. 321, 2020, 03013, DOI. 10.1051/matecconf/202032103013

[14]  Emmelmann, C., Sander, P., Kranz, J., and Wycisk, E., Laser Additive Manufacturing and Bionics: Redefining Lightweight Design, Physics Procedia, Vol. 12, 2011, pp. 364-368, DOI. 10.1016/j.phpro.2011.03.046.

[15]  Shan, X., Davies, C. M., Wangsdan, T., O’Dowd, N. P., and Nikbin, K. M., Thermo-Mechanical Modelling of a Single-Bead-On-Plate Weld Using the Finite Element Method, International Journal of Pressure Vessels and Piping, Vol. 86, 2009, pp. 110–121, DOI. 10.1016/j.ijpvp.2008.11.005.

[16]  Limpert, R., Brake Design and Safety, 3^rd Edition, SAE International, 2011

[17]  Orme, M., Gschweitl, M., Ferrari, M., Vernon, F., Yancey, R., Mouriaux, F., and Madera, I., A Holistic Process-Flow from Concept to Validation for Additive Manufacturing of Light-Weight, Optimized, Metallic Components Suitable for Space Flight, AIAA 2017-1540 58th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, 2017, DOI. 10.2514/6.2017-1540.