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Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints
- Source :
- Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 235:1703-1723
- Publication Year :
- 2020
- Publisher :
- SAGE Publications, 2020.
-
Abstract
- In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is in the front area of the Body-in-White, between the left-hand-side shock-tower and the Cross Car Beam, and its task is to support the steering column. The dash under investigation is an asymmetric rib-web aluminium casting part. The influence of Additive Manufacturing constraints together with modal and stiffness targets is investigated in view of mass reduction. The constraints drive the topology result towards a feasible and fully self-supporting Additive Manufacturing solution. A simplified finite element model of the steering column and of the Body-in-White front area is presented, and the limiting assumption of isotropic material for Additive Manufacturing is discussed. The optimization problem is solved with a gradient-based method relying on the Solid Isotropic Material with Penalization and on the RAtional Material with Penalization algorithms, considering the overhang angle constraint with given build directions. Three metals are tested: steel, aluminium and magnesium alloys. Topology optimization results with and without overhang angle constraints are discussed and compared. The aluminium solution, preferred for its lesser weight, has been preliminarily redesigned following the optimization results. The new dash concept has been validated by finite element considering stiffness, modal responses, and buckling resistance targets. The proposed dash design weighs 721 g compared to the 1537 g of the reference dash, with a weight reduction of 53%, for the same structural targets.
- Subjects :
- 0209 industrial biotechnology
Computer science
Automotive industry
Mechanical engineering
modal and equivalent static stiffness
02 engineering and technology
Design strategy
Cross car beam
020901 industrial engineering & automation
0203 mechanical engineering
Component (UML)
Dash
dash
topology optimization
buckling analysis
business.industry
Mechanical Engineering
Bracket
Topology optimization
Steering column
Finite element method
020303 mechanical engineering & transports
finite element
steering column
business
additive manufacturing
overhang angle constraint
Cross car beam, dash, steering column, topology optimization, additive manufacturing, overhang angle constraint, finite element, modal and equivalent static stiffness, buckling analysis
Subjects
Details
- ISSN :
- 20412983 and 09544062
- Volume :
- 235
- Database :
- OpenAIRE
- Journal :
- Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
- Accession number :
- edsair.doi.dedup.....ed8c60b11b4ee82973aa896da2428b39