This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Light Weighting of a Body Jig using Computational and Topology Optimization Methods
Technical Paper
2022-28-0062
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Simulations using computational techniques play a critical role in helping automotive industry adapt to light weighting and come up with future ready designs for maximizing the performance on cost and speed of manufacturing. As global legislation becomes increasingly stringent, light-weighting is a key element that will enable automotive OEMs to meet the emission goals towards net-zero future. Recent advancement in computational techniques like Topology Optimization have boosted the freedom of designers to reduce weight & cost of the part. This project discusses the development of computational models using physics-based software tools, and to validate the functional requirements to optimize the design using topology optimization techniques. The project also aims to reduce material consumption and manufacturing costs of the part while retaining its original stiffness. A case study was performed to design a body jig using field driven design which was proven to be a better way to generate & control complex part geometry by blending geometry with physics. Virtual additive print visualization tools were used to gauge the material consumption which would further improve the cost savings of the final optimized part. The designed part would be printed by Additive Manufacturing FDM techniques to validate the form, fit and functionality in actual condition. It was seen that this simulation process complements the current iterative and time-consuming design process & can be used for all future designs going forward.
Authors
Topic
Citation
Naik, A., shanmugam, S., and Desai, S., "Light Weighting of a Body Jig using Computational and Topology Optimization Methods," SAE Technical Paper 2022-28-0062, 2022, https://doi.org/10.4271/2022-28-0062.Also In
References
- Jasiuk , I. , Abueidda , D.W. , Kozuch , C. et al. An Overview on Additive Manufacturing of Polymers 2018 10.1007/s11837-017-2730-
- Bournias Varotsis , A. 2018 https://www.3dhubs.com/knowledge-base/introduction-fdm-3d-printing
- Rozvany , G. Topology Optimization in Structural Mechanics Berlin, Germany CISM International Centre for Mechanical Sciences; Springer 1997 322
- Bracket , D. , Ashcroft , I. , and Hague , R. Topology Optimization for Additive Manufacturing Proceedings of the Solid Freeform Fabrication Symposium Austin, TX 2011
- Sigmund , O. On the Usefulness of Non-Gradient Approaches in Topology Optimization Struct. Multidiscip. Optim. 43 2011 589 596
- How to Run a Topology Optimization - nTopology https://support.ntopology.com/hc/en-us/articles/360044051214-How-to-run-a-topology-optimization
- NX Topology Optimization Webinar - PROLIM 2020 https://www.youtube.com/watch?v=HXpx3XRYAxw
- Stratasys Direct 2018-2019 https://www.stratasysdirect.com/applications
- Lemu , H.G. 2018 10.1007/978-981-13-2375-1_15
- Naik , A. , Sujan , T. , Desai , S. , and Shanmugam , S. Light-Weighting of Additive Manufactured Automotive Fixtures through Topology Optimization Techniques SAE Technical Paper 2019-28-2544 2019 https://doi.org/10.4271/2019-28-2544
- Shanmugam , S. , Naik , A. , Sujan , T. , and Desai , S. Developing Robust 3d Printed Parts for Automotive Application Using Design for Additive Manufacturing and Optimization Techniques Incose International Symposium 2019-29 394 407 10.1002/j.2334-5837.2019.00694.x