Abstract
The paper presents the Finite Element Method (FEM) analysis of 3D-printed parts and further shape optimization. Information obtained from the static bending test allowed to carry out the FEM analysis in Siemens NX software with the Nastran module. The first part of the research was a comparative analysis of FEM analysis of a single specimen with real-life data collected for polylactide (PLA) specimens made in Fused Deposition Modelling (FDM) technology. The next step was FEM analysis of a PLA brake lever which is used in Silesian Greenpower electric vehicle. Silesian Greenpower team uses 3D-printing for rapid prototyping and manufacturing of customized parts of almost any shape for their car. Purpose of the Finite Element Analysis was to shape optimization of the lever in order to ensure adequate safety and ergonomics of use. The strains during its operation should not exceed the maximum permissible for the material used. As this is a key element of safety, a safety factor of level 3 has been adopted. FEM analysis contributed to weight reduction and shape optimization to withstand applied forces.
Highlights
Simulation is currently an integral part of design and manufacturing
European Journal of Engineering Science and Technology, 2 (1):59-64, 2019 conveniently. This has helped the finite element method become a powerful tool in modern mechanical engineering and manufacturing
Shape optimization allowed to reduce stress value in the inspected element from [59,37] MPa to [14,37] MPa – that means that stress value has been reduced by 75,8%. 3
Summary
Simulation is currently an integral part of design and manufacturing. Requirements set for manufacturers forces them to produce pieces that are lighter, more durable, easier to produce, cheaper and shape-optimised. Finite Element Analysis is a key simulation method nowadays. FEM has been developed in the 1960s, but lack of computer memory capable of billions of calculations made it wait for use until now. It has been widely used in solving structural, mechanical, heat transfer, and fluid dynamics problems as well as problems of other disciplines. European Journal of Engineering Science and Technology, 2 (1):59-64, 2019 conveniently This has helped the finite element method become a powerful tool in modern mechanical engineering and manufacturing. Silesian Greenpower team uses FEM analysis for manufacturing of customized parts, and for aerodynamic simulation (Fig. 1). On a basis of results of analysis of existence of Kammback aerodynamic effect innovative car body were modelled
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