Design and evaluation of direct metal laser sintered alloy automotive components for lightweighting -ID 1503

Project Member(s): Brown, T.

Funding or Partner Organisation: AutoCRC Ltd

Start year: 2015

Summary: 3D direct metal laser sintering (DMLS) of high strength metal alloys together with structural topological optimisation provides opportunities for automotive designers to design lightweight structurally efficient components. It has been observed that these methods, when applied by two separate and independent design teams, can produce very different designs despite the fact that they were designing the same functional component with very similar boundary conditions. Assessment of these structural components by an ¿experienced eye¿ generally leads to doubt about whether the component can actually perform as required. Literature review of use of DMLS for production of metal alloy components Develop knowledge and ability to conduct topological optimisation studies Carry out topological optimisation and FEA studies Investigate the sensitivity of the final design to changes in boundary conditions Design of automotive component specimen suitable for use in test rig and test vehicle at UTS Production of DMLS structural component(s) Carry out testing of DMLS produced automotive component. Record and evaluate test data. Compare test results with simulation

Keywords: topological optimisation, automotive, 3D printing, direct metal laser sintering

FOR Codes: Automotive Engineering Materials, Automotive Equipment, Automotive engineering materials

Acknowledgement of Country

UTS acknowledges the Gadigal people of the Eora Nation, the Boorooberongal people of the Dharug Nation, the Bidiagal people and the Gamaygal people, upon whose ancestral lands our university stands. We would also like to pay respect to the Elders both past and present, acknowledging them as the traditional custodians of knowledge for these lands.