Rediseño mecánico con optimización topológica de las manguetas para el prototipo fórmula SAE de la carrera de Ingeniería Automotriz

Abstract

Through reverse engineering, the journals were redesigned with the aim of reducing weight to be light and resistant, this process was carried out by using CAD software for modelling, CAE for topological optimization and validation of results, aluminium 7075 alloy casting were used to manufacture of the new journals. The redesign of the journals initiated by the analysis in the original piece, obtaining geometrical parameters for the new model in CAD software. The ANSYS Workbench was used to optimize and simulate the new journals; software which employs the finite element method as a technique for the reduction of unnecessary material from the new front and rear journals by 70%, this percentage represents a design factor in 3.22 and 5.16 respectively. The manufacturing process began with additive manufacturing (3D printing) of the final design and to make the moulds in green sand, the aluminum alloy 7075 was made in a crucible furnace with an average temperature of 910 °C with metals such as Chromium (0.18-2)%, Copper (1.2-2)%, Magnesium (2.1-2.9)%, Zinc (5.1-6.1)% and small percentages of iron, silicon, titanium and other metals, thus obtaining the journals. As a final result, a reduction of the weight in the journal is obtained by 53% lower than the original, represented for the front journal of 2.4 lb and for the rear of 2.2 lb. It is concluded that small, resistant parts can be obtained through an appropriate alloy and a moderately economic production cost. It is recommended in the design of the model to perform the respective exit angles and appropriate measures to avoid contractions of the material.