Simuleringsbasert-design for fullutnyttelse av additiv tilvirkningJørgen Eliassen | MSc. Mechanical Engineering

Conventional design: Iterative

ConceptDesign

ProposalSimulation

Design Iteration

#?

ProductionVerification

Simulation-based design: Direct

Design Space

FE ModelOptimization

SetupFE

ValidationPre-

Processing

Manufacturing Constraints

DfAM

• Dynamic wheel loads

• Weight• Stiffness

Uprights: Result SummaryFront

• Weight: 679g

• Deflection: 0.1mm peak during

cornering (lateral direction)

• CPU time: 24h 30min

Rear

• Weight: 550g

• Deflection: 0.1mm peak during

cornering (lateral direction)

• CPU time: 48h 27min

• Material: Ti-6Al-4V

• Production: AM (DMLS) combined with

CNC-machining

Uprights: Result SummaryFront

• Weight: 679g

• Deflection: 0.1mm peak during

cornering (lateral direction)

• CPU time: 24h 30min

Rear

• Weight: 550g

• Deflection: 0.1mm peak during

cornering (lateral direction)

• CPU time: 48h 27min

• Material: Ti-6Al-4V

• Production AM (DMLS) combined with

CNC-machining

Upright: Design Process

1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process

1. Design domain

Suspension movement

Interfacing components

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

Ti-6Al-4V (titanium grade 5)

Density

Elastic modulus

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

Top-down combined with bottom-up

Structured hexahedral elements

1 070 000 elements

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

Top-down combined with bottom-up

Structured hexahedral elements

1 070 000 elements

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

Suspension points

Mounting bracket

Brake caliper

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

Wheel bearing reaction forces

Mapped analytical fields

Quasi-static scenarios

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

Sensitivity-based algorithm

Minimum compliance problem

Weight target

7. Pre-processing

8. CAD regeneration

9. FE Validation

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

Filtering

Smoothn

8. CAD regeneration

9. FE Validation

Front Rear

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

Modifications for mounting holes

Inclusion of additional geometric

details (motor mount, seal slots etc.)

9. FE ValidationFront Rear

Upright: Design Process1. Design domain

2. Properties

3. Mesh

4. Interactions

5. Loads and boundary conditions

6. Optimization

7. Pre-processing

8. CAD regeneration

9. FE Validation

Dimensioning load scenario

Extremal load scenario

Non-linearites (contact, pretension) Front Rear

Upright: Manufacturing Process

1. Additive Manufacturing (DMLS)

Custom support structure design

Build quality

Build time

Waste material

2. CNC Machining

Front upright AM-build illustration. Red color indicates supports generated by Magics (AM-software) – Tronrud Engineering AS

Upright: Manufacturing Process

1. Additive Manufacturing (DMLS)

Custom support structure design

Build quality (overhangs)

Build time

Waste material

2. CNC Machining

Front upright after AM and heat treatment, built on the EOS M280 machine at Tronrud Engineering AS

Upright: Manufacturing Process1. Additive Manufacturing (DMLS)

2. CNC Machining

Tolerances

Wheel bearing run out

Position tolerances for all

mounting holes

Fit tolerances

Perpendicularity

Surface finishes

Threading

Upright: Manufacturing Process1. Additive Manufacturing (DMLS)

2. CNC Machining

Tolerances

Wheel bearing run out

Position tolerances for all

mounting holes

Fit tolerances

Perpendicularity

Surface finishes

Threading Precision CNC-machining by HTS Maskinteknikk, Drammen – Norway

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