Topology Optimization and Additive Manufacturing of Automotive Component by Coupling Kinetic and Structural Analyses
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ght © 2020 KSAE/ 11812 pISSN 12299138/ eISSN 19763832
TOPOLOGY OPTIMIZATION AND ADDITIVE MANUFACTURING OF AUTOMOTIVE COMPONENT BY COUPLING KINETIC AND STRUCTURAL ANALYSES Gyu-Won Kim, Yeong-Il Park and Keun Park* Department of Mechanical System Design Engineering, Seoul National University of Science & Technology, Seoul 01811, Korea (Received 4 November 2019; Revised 13 January 2020; Accepted 17 February 2020) ABSTRACTTopology optimization is a shape optimization method connected with finite element (FE) analysis, and has recently received increasing attention owing to rapid evolution of additive manufacturing (AM). In this study, an automotive knuckle part was developed by combining kinetic analysis, FE structural analysis, and topology optimization. A kinetic analysis based on a multibody dynamics simulation was performed to calculate reaction forces during a given driving course. Structural FE analyses were conducted to evaluate structural safety by applying the calculated reaction forces as boundary conditions. Topology optimization was then carried out to improve the stiffness and structural safety of the knuckle. Further structural FE analyses were performed to compare the structural efficiency of the optimized design where the stiffness increased more than 2.5 times in comparison with the original design. The optimized knuckle pairs were then manufactured by a metal AM process using AlSi10Mg powders, and were assembled to the other suspension components successfully. A formula-style electric car was then built by assembling the developed knuckle, and a number of driving tests showed that the knuckle ensured adequate structural stiffness and safety. KEY WORDS : Topology optimization, Finite element analysis, Multibody dynamics simulation, Additive manufacturing, Formula-style car
NOMENCLATURE t FV FH mf m0 m δf k* λ
design stages where design changes significantly impact the performance of the final structure (Deaton and Grandhi, 2014). Because two conflicting objectives of weight reduction and structural safety can be satisfied together, topology optimization has attracted increasing attention in the designs of lightweight automotive components (Yildiz, 2008; Cavazzuti et al., 2011; Yoo et al., 2017). In spite of the usefulness of topology optimization, however, it has a limitation that the optimized topology is too complicated to be fabricated by traditional manufacturing processes. This limitation has recently been overcome by the rapid evolution of additive manufacturing (AM) technologies (Lim et al., 2017). AM, also known as three-dimensional (3D) printing, has high design flexibility in comparison with traditional manufacturing processes. By utilizing the design flexibility of AM, topologically optimized designs can be easily manufactured without additional geometric constraints (Zegard and Paulino, 2016). Various studies have utilized AM to manufacture topologically optimized designs with complicated shapes (Gaynor et al., 2014; Langelaar, 2016; Park et al., 2019). To apply topology optimization t
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