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Design optimization for an additively manufactured automotive component

Abdi, Meisam; Ashcroft, Ian; Wildman, Ricky D.

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Authors

Meisam Abdi

IAN ASHCROFT IAN.ASHCROFT@NOTTINGHAM.AC.UK
Professor of Mechanics of Solids

RICKY WILDMAN RICKY.WILDMAN@NOTTINGHAM.AC.UK
Professor of Multiphase Flow and Mechanics



Abstract

The aim of this paper is to investigate the design optimization and additive manufacture of automotive components. A Titanium brake pedal processed through Selective Laser Melting (SLM) is considered as a test case. Different design optimisation techniques have been employed including topology optimization and lattice structure design. Rather than using a conventional topology optimization method, a recently developed topology optimization method called Iso-XFEM is used in this work. This method is capable of generating high resolution topology optimised solutions using isolines/isosurfaces of a structural performance criterion and eXtended Finite Element Method (XFEM). Lattice structure design is the other technique used in this work for the design of the brake pedal. The idea is to increase the stability of the brake pedal to random loads applied to the foot pad area of the pedal. The use of lattice structures can also significantly reduce the high residual stress induced during the SLM process. The results suggest that the integration of the design optimization techniques with a metal additive manufacturing process enables development of a promising tool for producing lightweight energy efficient automotive components.

Citation

Abdi, M., Ashcroft, I., & Wildman, R. D. (2018). Design optimization for an additively manufactured automotive component. International Journal of Powertrains, 7(1-3), https://doi.org/10.1504/IJPT.2018.090371

Journal Article Type Article
Acceptance Date Jul 24, 2017
Publication Date Jan 1, 2018
Deposit Date Oct 23, 2017
Publicly Available Date Mar 28, 2024
Journal International Journal of Powertrains
Print ISSN 1742-4267
Electronic ISSN 1742-4275
Publisher Inderscience
Peer Reviewed Peer Reviewed
Volume 7
Issue 1-3
DOI https://doi.org/10.1504/IJPT.2018.090371
Keywords topology optimization; lattice structures; additive manufacturing; automotive; powertrain; XFEM; selective laser melting; SLM
Public URL https://nottingham-repository.worktribe.com/output/963665
Publisher URL https://www.inderscienceonline.com/doi/abs/10.1504/IJPT.2018.090371

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