Abstract
The weight optimization of a structure can be conducted by using fewer and downsized components, applying lighter materials in production, and removing unwanted material. Topology optimization (TO) is one of the most implemented material removal processes. In addition, when it is oriented towards additive manufacturing (AM), it increases design flexibility. The traditional optimization approach is the compliance optimization, where the material layout of a structure is optimized by minimizing its overall compliance. However, TO, in its current state of the art, is mainly used for design inspiration and not for manufacturing due to design complexities and lack of accuracy of its design solutions. The authors, in this research paper, explore the benefits and the limitations of the TO using as a case study the housings of a front and a rear brake caliper. The calipers were optimized for weight reduction by implementing the aforementioned optimization procedure. Their housings were topologically optimized, partially redesigned, prepared for 3D printing, validated, and 3D printed in titanium using selective laser melting (SLM). The weight of the optimized calipers reduced by 41.6% compared to commercial calipers. Designers interested in either TO or in automotive engineering can exploit the findings in this paper.
Highlights
The reduction of car weight is a topic of high importance in the automotive industry.A lighter car has an increased acceleration, and an improved performance
The weight optimization problem was confronted as a three-folded problem; using less and downsized components, applying lighter materials in production, and removing unwanted material
The final designs with their technical details and the tolerances should take into account both the material selection and the production method
Summary
A lighter car has an increased acceleration, and an improved performance. This weight reduction reduces material cost, improves fuel efficiency, as well as reduces vehicle exhaust emissions. According to Li, et al [1], for every 100 kg weight reduction of light transport vehicles (LTV), their fuel consumption will be decreased on average by approximately 0.4 L/100 km, and their CO2 emissions will be mitigated by 8–11 g/km. There are several ways to reduce car weight, such as the use of lighter materials in manufacturing, the downsizing of the car, and the removal of unwanted material from car components [2]. One of the most implemented material-removal methods is topology optimization (TO)
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
