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

journal article in Web of Science

en

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.

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.

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

14.10.2019

Emerald Publishing Limited

Bingley, United Kingdom

1355-2546

25

9

1545–1551

7