To implement the CAD platform-based approach of Design for Additive Manufacturing (DfAM) and validate it in a real case, an entire design optimization process of a Formula SAE front brake caliper has been performed, to be printed by Powder Bed Fusion (PBF) process. The DfAM consists in the use of a Ti6Al4V titanium alloy to better resist at high temperatures and a topology optimized shape allowed by the technology to save weight despite the density increase. Structural and thermal behavior has been discussed. DfAM process-specific techniques have been implemented for internal geometrical features and optimized shapes. The design for additive workflow is presented and finally the exploited design approach based on a CAD platform is synthesized.
Design for Additive Manufacturing of a Topology Optimized Brake Caliper Through CAD-Platform-Based Systematic Approach / Dalpadulo, E.; Pini, F.; Leali, F.. - (2021), pp. 92-97. (Intervento presentato al convegno 10th International Joint Conference on Mechanics, Design Engineering and Advanced Manufacturing, JCM 2020 tenutosi a n/a nel 2020) [10.1007/978-3-030-70566-4_16].
Design for Additive Manufacturing of a Topology Optimized Brake Caliper Through CAD-Platform-Based Systematic Approach
Dalpadulo E.;Pini F.;Leali F.
2021
Abstract
To implement the CAD platform-based approach of Design for Additive Manufacturing (DfAM) and validate it in a real case, an entire design optimization process of a Formula SAE front brake caliper has been performed, to be printed by Powder Bed Fusion (PBF) process. The DfAM consists in the use of a Ti6Al4V titanium alloy to better resist at high temperatures and a topology optimized shape allowed by the technology to save weight despite the density increase. Structural and thermal behavior has been discussed. DfAM process-specific techniques have been implemented for internal geometrical features and optimized shapes. The design for additive workflow is presented and finally the exploited design approach based on a CAD platform is synthesized.
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