Combined application of topological optimization method and additive technologies for fast modernization of wheeled vehicle load-carrying systems

Introduction (problem statement and relevance). In the process of refining or modernizing vehicles, changes in vehicle packaging or unit composition are inevitable. At the same time, the process of redesigning the load-carrying system shall be time-efficient and shall include minimum number of changes, while maintaining the required safety margin, durability and stiffness levels in the design. Combined application of topological optimization method and additive technologies (e.g. metal casting in 3D printed sand molds) can ensure that such requirements are met without significantly increasing weight of the load-carrying system.

 The purpose of the study is estimation of labour intensity of the process of modernization of load-carrying systems under conditions of frequent changes of packagings and units by means of combined application of topological optimization method and additive technologies, as well as comparison of this process with traditional designing based on manual construction of load-carrying systems with the use of assortment (sheets, profiles) and assembly operations (riveting, welding, etc.).

 Methodology and research methods. The object of research is a load-carrying frame of a driverless load trolley designed by topological optimization method. Some units of the load trolley – steering gear and drive systems – were changed, which required refinement of the load-carrying system to adapt to the new packaging of the vehicle. A method was developed and described for quick refinement of the load-carrying system to adapt to the new packaging space using topological optimization and taking into account additive manufacturing – casting of aluminum alloy AK7ch into 3D-printed sand molds.

 Scientific novelty and results. Results of checking calculations of strength, stiffness and stability were presented for the newly designed and initial frames. Comparative analysis was carried out for the initial and modernized frame geometry. Advantages and peculiarities were listed for combined application of topological optimization method and additive technologies compared to manual design for traditional technologies. Practical significance of the study is that the developed procedure for refinement of load-carrying systems allows considerable acceleration of the process of design adaptation for frequently changing packaging. It is shown that the designs obtained using this method do not degrade or worsen the weight and strength characteristics of load-carrying systems, while their geometry has no global changes in terms of the loading pattern.

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