Detail publikace

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

VAVERKA, O. KOUTNÝ, D. PALOUŠEK, D.

Originální název

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

Typ

článek v časopise ve Web of Science, Jimp

Jazyk

angličtina

Originální abstrakt

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.

Klíčová slova

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

Autoři

VAVERKA, O.; KOUTNÝ, D.; PALOUŠEK, D.

Vydáno

14. 10. 2019

Nakladatel

Emerald Publishing Limited

Místo

Bingley, United Kingdom

ISSN

1355-2546

Periodikum

RAPID PROTOTYPING JOURNAL

Ročník

25

Číslo

9

Stát

Spojené království Velké Británie a Severního Irska

Strany od

1545

Strany do

1551

Strany počet

7

URL

https://www.emerald.com/insight/content/doi/10.1108/RPJ-07-2018-0171/full/html

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",
  journal="RAPID PROTOTYPING JOURNAL",
  year="2019",
  volume="25",
  number="9",
  pages="1545--1551",
  doi="10.1108/RPJ-07-2018-0171",
  issn="1355-2546",
  url="https://www.emerald.com/insight/content/doi/10.1108/RPJ-07-2018-0171/full/html"
}