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Then the advantages of combining TO and AM are highlighted. In the first part of the present work topology optimization approach is presented.

The aim is to also investigate if an optimization on the aluminium component gives feasible results, or changing to steel can be an economical option even with an increase in the weight. If the reduction of weight is not followed by effectiveness from the technical and economical point of views, the design option cannot be selected. The aim is to reduce weight and improve the performance by changing to titanium, but other aspects need to be taken into account. An investigation of topology optimization results carried out on Alumec 89 (the original material for the upright), titanium alloy Ti6Al4V and steel AISI 4142 is performed.

In this project the optimization of an automotive upright is performed, in order to take advantage to reduce its weight. However, the potential of TO can be only exploited if combined with AM, since the results given by the topology optimization simulations are sometimes complex shapes, which can be produced only by the AM process regardless of the layout of the part being fabricated. It helps to reduce the weight of the structures while keeping the same performance, or even enhancing it. Aerospace and automotive industries are trying to exploit AM, to obtain high performance with weight and cost savings.įull potential of design freedom can be realised by making effective use of topology optimization (TO). Another benefit is the reduction of waste material. The first consequence of using such techniques is the freedom of design that can be assigned by the designer, thus implying the production of complex parts. The introduction of metals among the materials available to manufacture parts led to revolutionary developments in the manufacturing field. These techniques are referred to as 3D printing or Additive Manufacturing (AM). 2016 (English) Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE credits Student thesis Abstract ĭuring the past years, new production processes have been developed which build adding step by step layers on the previous ones.