Additive Manufacturing of a Topology Optimized Automotive Flange Fork – A Step Towards Cleaner Production of Automotive Components

Abstract

Abstract The sustainable replacement of automotive manufacturing sector is necessary to strengthen the sustainable development goals. Additive manufacturing (AM) equipped with topology optimization is known for fabricating components with reduced material and energy. In this study, the automotive flange fork is fabricated using laser-based powder bed fusion process (L-PBF). The topology optimization is carried out using the Ntopology software to generate two designs (i.e., design – 1 and design – 2) with the volume reductions of 26% and 46%, respectively. The compressive stresses exerted on the shaft and on the chassis by both the optimal designs of flange fork are examined using the finite element analysis (FEA). Considering the factor of safety of 2.5, design – 1 was found to be the optimal choice. The design is fabricated with the L-PBF using Inconel-718 material. Manufacturing quality analysis of the component shows the hatch distance of printed sample to be 18% lower than the set parameter. This difference was attributed to the non-homogenous size of the powder particles. Furthermore, the fabricated component is tested for its efficiency to withstand the torque of 300 Nm which is generated in most of the 4-wheeler automobiles. The torque analysis successfully demonstrated component’s ability without damage or cracks.