001-INTEGRATED Process For An Automotive component-LEALI
001-INTEGRATED Process For An Automotive component-LEALI
001-INTEGRATED Process For An Automotive component-LEALI
https://doi.org/10.1007/s12008-020-00684-7
ORIGINAL PAPER
Received: 13 April 2020 / Accepted: 25 July 2020 / Published online: 3 August 2020
© Springer-Verlag France SAS, part of Springer Nature 2020
Abstract
Use of Additive Manufacturing provides great potentials to settings focused on high performance products. It allows feasibility
of sundry innovative features to completely rethink geometries and shapes and it leads to embrace new design approaches.
The enhanced design freedom can be exploited to optimize products, using techniques such as topology optimization. The
study of methods for development of optimized components to be produced by AM becomes therefore fundamental. A
framework for the methodological approach to operations to be carried out from the concept model to the printed component
has been analyzed and it is clear that issues and research efforts relapse both the global level of the workflow and the local
level of singular tasks to be performed. Problems related to management of Design for Additive Manufacturing workflow
can be solved with holistic approach, through the use of computer aided integrated tools. The aim of this work is to test the
effectiveness at local level of such tools with respect to operations for both design and industrialization optimization, working
on an automotive case study. In particular, specific tools for topology optimization, product simulation, printing preparation
and process simulation are taken as reference and results obtained with an integrated CAD platform are discussed.
Keywords Design for Additive Manufactruing · CAD based integrated platform · Powder Bed Fusion · High performance
automotive components
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order to perform design optimization. Some advantages of 2 Design for Additive Manufacturing
these methods, together with innovative metallic alloys use, workflow
are the possibility to obtain extremely light structures, such
as free-form topology optimized parts. The design of parts specifically thought to be produced by
AM technologies, according to Design for Manufacturing
[10], is challenging and consequently, the development of
knowledge, skills, rules, tools, processes and methodolo-
1.2 Topology optimization gies to fully benefit of AM become fundamental, as shown
by Thompson et al. [2]. The DfAM fulcrum is both design
This kind of design-optimized parts usually has excellent and product optimization. As subset of Design for X (DfX)
performance from a structural point of view, in terms of [18], DfAM requires that the effects of design on manu-
weight/stiffness or weight/strength ratio. Topology optimiza- facturing and vice-versa have to be taken into account to
tion is a numerical technique to calculate optimal material optimize product performance and quality minimizing devel-
distributions, so that the material can be positioned only opment and production time and costs. Firstly, there are
where needed, to achieve established structural performance challenges in embracing new design approaches and in the
according to set targets and constraints. First contributes use of specific design rules and tools, preventing the users
of its theoretical definition have some tens of year and exploiting completely the potentials of the technology. Sec-
are due to Bendse and Kikuchi [12], but despite the tech- ondly, even though the use of additive technologies firmly
niques are known approaches [13] their application on design joins a CAD mathematical model and the actually printed
of real parts has been thwarted and part performance has component, the workflow from the concept to the definitive
been compromised due to both design tools, manufactur- job results in many sequential steps which may have complex
ing and technological constraints. Implementation of AM and slow relationships [19]. With respect to the development
makes these approaches more flexible since the construction of topology optimized metal parts to be printed by Powder
of a freeform organic part becomes feasible and thus, Topol- Bed Fusion (PBF) processes, the DfAM general workflow is
ogy optimization is having a great trend. In order to create depicted in Fig. 1. The basis of DfAM workflow is an itera-
optimized parts, sunder numerical methods can be applied tive refinement of the starting model of the part with respect
to compute ideal geometries [14] and some of them are to Design and Industrialization constraints to respectively
currently implemented in specific Computer Aided Engineer- improve the part shape and the associated printing process,
ing (CAE) software. Design of topology optimized parts is as the Authors firstly tried to define it in [20]. The input is
increasing especially in medical engineering, aerospace and the Product Data, which is made of the information (mod-
automotive settings, different design approaches and meth- els, analyses, objectives, constraints) that are required for the
ods are being explored in order to fully exploit the aforesaid design. The output is the Production, or rather the 3D printing
potentials induced by AM technologies [15,16]. The idea is to process and the other related operations (e.g. post processing,
re-think both products and their development methods, thus, CNC machining and testing). The whole approach relies on
the Design for Additive Manufacturing (DfAM) is receiving specific tasks listed as follow.
an increasingly attention [17].
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in the four local levels, are detailed below. In order to com- assessment approach for local level steps. Chapter 4 provides
pute a topology optimization, firstly it is necessary to import the results on the case study achieved with respect to each
a geometrical model and to define the design space and of the specific tasks, that are lastly highlighted in the final
non-design space areas. It is then required to setup a finite discussion in the Chapter 5.
element model, composed by a mesh of the part and the sets
of restraints and loads to replicate part physical behavior.
The targets and constraints for the optimization need to be
specified, a geometrical result must be obtained from com- 3 Case study, tools and assessment approach
putation and hopefully a validation of this should be carried
out. Product Simulation is especially performed in that sense, In order to implement the described method on the integrated
a generic geometrical model has to be imported and the finite tool and validate it at local level, a case study is represented by
element model must be set in the same way, particular simula- a Formula SAE wheel knuckle. This component is a key part
tion modes should be possible as well as material definition for vehicle dynamics performance in racing cars, since non
could be deepened. A key point is the result analysis with suspended masses have to be minimized in order to guarantee
post-processing features. Printing Preparation requires the cornering performance, due to the better tarmac-tyre contact.
machine definition and the possibility to manipulate input Dumbre et al. [22] analyzed wheel knuckle behavior in criti-
geometries (such as STL). Tasks such as part positioning, cal working conditions and defined a modeling approach for
part orientation and support generation are necessary, as simulations. Actually, sundry examples of design optimiza-
well as slicing computation is mandatory, moreover, tools tion of this component have been explored. Generally, this
for slicing analysis are useful. Consequently, it is necessary is done embracing traditional technologies and, for exam-
to export the data for build processors or in printing format ple, Bhardwaj et al. worked on the design optimization for
if this is integrated in the software. In order to perform the a part to be produced by CNC milling [23], while Harzheim
Process Simulation, an industrialized job has to be imported et al. achieved the optimization for a part to be produced by
and material temperature-dependent data and process-related casting [24]. Conversely, few examples of DfAM including
machine parameters must be specified. A mesh of the job and topology optimization of a wheel knuckle to be produced by
its connections have to be created and computation settings PBF AM process exist, such as the Electron Beam Melting
which reflects the process have to be defined. Finally, some manufactured one from Walton et al. [25].
post-processing features are required to analyze the result and The case study part, originally made by traditional sub-
tools to manipulate it should be significant. The described tractive technology, had been re-designed requiring the use
tasks require express implementation in tools and since they of many specific software for the different tasks, and then
affect the workflow at local level, Topology Optimization, printed by Selective Laser Melting (SLM) PBF AM process
Product Simulation, Printing Preparation and Process Simu- with benefit of weight reduction. According to the work-
lation have to be tested. flow above described (see Fig. 1), the steps and the related
Therefore, the aim of this work is to implement the general results for benchmarked part are depicted in Fig. 2. The
method, understanding the behavior of the integrated tool at tools involved for the benchmarked part operations are listed
local level. The next chapter presents the integrated CAD as follow. Dassault Systmes Solidworks had been used for
based platform that has been tested for Design and Industri- CAD modelling and re-design operations, Altair Optistruct
alization phases with respect to a selected case study and the for topology optimization, MSC Marc for Product Simula-
tion, Materialise Magics for Printing Preparation, PTC Creo
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for CAD industrialization re-design operations, MSC Simu- Table 1 Loadcases definition
fact Additive for Process Simulation. Conversely, the CAD Loadcase Element Value [unit]
based platform selected for the local level evaluation is the
Dassault Systmes 3DExperience. The CAD based platform Bump Acceleration 5.6 G [m/s2 ]
fundamentally integrates the design environment of Catia Vertical force 4400 [N]
suite, with CAX engineering tools of Simulia and Delmia Cornering Acceleration 2.5 G [m/s2 ]
and PLM management of Enovia. Drift force 4400 [N]
Vertical force 2810 [N]
3.1 Local level evaluation approach Drift moment 961 [Nm]
Reaction moment 809 [Nm]
For each of the core tasks of Design and Industrialization Braking Acceleration 3 G [m/s2 ]
phases, output of the standalone tool at the state of art has Longitudinal force 2700 [N]
been identified as reference. This becomes the target for Vertical force 1805 [N]
the operations performed in the CAD platform through the Braking moment 885 [Nm]
respectively use of specific apps, summarized in Fig. 3). With Transport moment 616 [Nm]
respect to the first step, the output of Altair Optistruct is taken
as reference. The 3DExperience application for this purpose
is Catia Functional Generative Design, which integrates in
a CAD environment Tosca solver to perform topology opti- performance. In particular, the original CNC-machined part
mization and compute the shapes computed. The aim is to had some stress concentrations over 300 MPa.
replicate the set up of three different loadcases and discover During part utilization and stress this behavior could lead
if the tools, starting from the same input data, will provide to crack trigger on the material and eventually part fail-
similar results despite of different features and computational ure. During the re-design operations, exploiting the branched
algorithms. In details, bump is the first loadcase; it simulates organic shape, particular attention had been put to the limita-
the maximum load related to a vertical acceleration. The cor- tion of part stress at 200 MPa and the product simulation
nering loadcase is to simulate the load of a corner at high upheld that part behavior. The output results are the Von
speed with the maximum lateral acceleration (tyre limit con- Mises stress distribution maps. The 3DExperience applica-
dition). Braking is the loadcase that simulates the load due tion for structural validation is Simulias Linear Structural
to the maximum negative longitudinal acceleration. Table 1 Validation, which involves Abaqus computation code. The
summarizes the loadcases definition. With respect to the sec- output of Materialise Magics is taken as reference for the
ond step, the output of MSC Mark is taken as reference. The third step. The job had been created introducing the part in the
wheel knuckle prototype had been validated through finite machine context, computing a precise orientation, designing
element (static and buckling) analysis simulations, in order special support structures and performing slicing analysis.
to check, despite the mass saving, the adequate structural The benchmarked job preparation had required part orienta-
Fig. 3 Standalone tools and platform apps involved in Design and Industrialization core tasks
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tion to be optimized in order to minimize the need of supports, – RBE2 on the holes #4 with X and Z displacement on the
so that much less powder will be required (material, time and control node at the center of the joint.
costs reduced) and the post processing step will be simpli- – RBE2 on the holes #5 with Z displacement on the control
fied. For support definition, both traditional vectorial support node coincident with the pivot axis.
from Magics library and CAD-designed solid supports had
been introduced. Solid supports provide material saving and In the Functional Generative Design application, the fol-
let reduction of support anchoring on part surfaces. A total lowing setup has been created:
amount of 205 supports between block and cone type had
been used both vertical ones and angled ones, with the aim – Spherical joint on the axis of the holes #1 positioned on
of reducing part surface support anchor. The aim is to repli- the center of the joint, with X, Y and Z displacement.
cate the operations that brought the industrialized additive – Forbidden displacement on holes #4 with control node
manufacturing job and verify if the Delmias Powder Bed positioned between the two axis and X and Z displace-
Fabrication application on 3DExperience, despite of differ- ment.
ent interfaces and features, could lead to a similar result. – Forbidden displacement on holes #5 with control node
Finally, the last step refers to the output of Simufact. Process positioned between the two axis and Z displacement.
simulation had been performed starting from the industrial-
ized job made in Magics, exported as STL. Voxel mesh and First and third cases return identical solutions, whereas
connections had been created, thermo-mechanical AlSi10Mg the second case provides a comparable solution, except for
material properties had been set, process parameters and tem- the loss of a small lever arm. The benchmarked loads setup
peratures had been created, thermal and structural analyses was made of a RBE3 element connected with the surfaces
had been performed considering the phases from building to of #3, with control node positioned at the wheel center.
cooling. The simulation tool had been calibrated with pro- On this element all the loads (force and torque) related
cess parameters of the SLM 280 HL machine used for part to the three different loadcases had been applied. In the
production and via experimental optimization. The aim is to Functional Generative Design application, feature for remote
run a preliminary process simulation, completing the opera- load and remote torque have been used, connected with the
tion to achieve the same type of result, which is in particular a surfaces of #3 applied on a point positioned at the wheel
displacement map and a deformed model. The 3DExperience center, as depicted in Fig. 4b. The computation targets are
application is Simulias Additive Manufacturing Scenario. In the results from the bump, cornering and braking loadcases
this case the expected output should not be exactly compa- above described. With respect to the last two shape com-
rable, since simulation will require then special additional putations, the introduction of the brake caliper is required,
tuning. since it contribute to the knuckle stiffness. A simulacrum
is created and fit in assembly with the wheel knuckle, the
mesh of both parts are created and they are connected intro-
ducing infinitely-stiff elements on the holes #2. In addition,
4 Results
for the braking loadcase, forces acting on the braking pads
are applied on the part. Topology optimization is set with a
4.1 Topology optimization
stiffness maximization target (minimization of element com-
pliance) and a target percentage mass value as constraint.
A tetrahedron linear mesh with cell dimension of 2 mm has
Figure 5 depicts respectively the results from Optistruct and
been created in order to balance an accurate solution and
3DExperience, with respect to the Bump (Fig. 5a), Cornering
computational cost. The structural model has been developed
(Fig. 5b) and Braking (Fig. 5c) loadcases.
in order to replicate the physical behavior of the suspension
mechanism. Figure 4a depicts the reference model of the
4.2 Product simulation
component with the main geometrical features used to setup
the optimization. Specifically, the holes for fastening the
The operations in 3DExperience can be performed on Func-
brackets for uniballs of upper and lower wishbones, respec-
tional Generative Design itself (if platform workflow is
tively #1 and #4; holes for fastening the bracket that connects
preserved) or anyway in Linear Structural Validation applica-
the steering rod, #5; housing of the wheel bearings, #3; holes
tion. For the finite element analysis, a truss rod link between
for the screws that bolt the brake caliper, #2.
the holes for the fastening of the brake caliper has been intro-
The benchmarked restraints setup was made of:
duced in order to replace the part taking into account its
stiffness (Fig. 4b). The three loadcases (Bump, Cornering
– RBE2 on the holes #1 with X Y and Z displacement on and Braking) have been simulated using the Linear Struc-
the control node at the center of the joint. tural Validation application, keeping the setting of the finite
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Fig. 4 Component reference model with main geometrical features (a) and finite element model (b)
element model used for the topology optimization (Fig. 4b), have set the self-supporting angle, selecting the setup of the
including loads and constraints, except for the mesh size. optimization to minimize supports. For support generation,
Figure 6 shows the stress distribution analysis obtained vectorial supports from libraries are analogue (see Fig. 7c),
respectively with Marc (Fig. 6a) and 3DExperience (Fig. 6b) but only Wired and Cones can be angled. The design of solid
for the Bump loadcase and the finite element model setup on supports is facilitated by the platform environment integra-
3DExperience to perform product simulation. tion, but the actual use of them is compromised since the
interposing of elements between those and the part is possi-
4.3 Printing preparation ble only for Cone and Tree types. Finally, about 157 supports
and a mixed of cones, wired and volume, both vertical and
On 3DExperience Powder Bed Fabrication application, angled have been introduced. Since solid supports are able
firstly setup of the virtual machine environment is required, to support Cones but not Wired, they should be replaced by
defining several building parameters related to the manu- Wired support type. Additional slicing analysis is required
facturing process (build volume, build tray, scanning type, in order to check effectiveness of supporting structures and
slicing step, recoating direction, recoating speed etc.). Part their refinement. Moreover, the slicing and scan path can
orientation can be computed in the same way as Magics, once be defined, with information about the recoater for powder
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deposition, the inert gas flow and scanning strategies, pat- alignment with the original CAD model, showing respec-
terns and sequences. The generated path can be analyzed tively Simufact and 3DExperience results.
so that low melting and roughness points of each slice can
be displayed in order to optimize the printing preparation.
Figure 7 depicts the industrialized job obtained with Magics
(Fig. 7a) and 3DExperience (Fig. 7b). 5 Discussion
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