Description
Generative design is used as an optimization technique to achieve a reasonable trade-off between weight and reliability for the control arm plate of a double wishbone suspension assembly of a Formula Student race car. Generative design is applied in order to develop a low-weight design alternative to a standard control-arm-plate design. In addition to an optimal material distribution, the generative design methodology provides several design outcomes for different materials and fabrication techniques. Based on the generative design recommendation, the print was developed with Ti-6Al-4V using SLM 280 2.0, which deposits layers of 60 ?m thickness, by employing a bidirectional powder recoating technology. The entire printing process is conducted in an inert atmosphere, filled with argon gas, with two 400 W IPG fiber lasers that scan the layers at a build rate of 113 cubic cm/hr. And the support removal is conducted using wire cutting.
Key Learnings
- Learn how to apply generative design for lightweighting.
- Learn how generative design provides an alternative design solution to long periods spent in the design phase.
- Generative Design gives optimized designs and the same can be structurally analyzed.
- Learn how the approach implemented provides a justifiable outcome for a weight factor of safety (FOS) trade-off.