Leveraging on the capabilities of AM, Stier Racing team zooms ahead to victory. Electric vehicles produce fewer Part Count Reduction, is a new emissions that contribute to climate approach to designing parts where change than the average an optimized, monolithic part, conventional vehicles. Formula Green replaces a multi- is a motorsport competition in which component assembly. Through students from universities all over the additive manufacturing,the rear country compete with a life-size wheel hubs were redesigned to Formula-style electric vehicle (EV). accommodate the constant velocity The aim is to design and build a (CV) axle at the CV joint interface. The single-seater EV which races on a rear wheel hubs for the race car were course. Students are evaluated in 3D printed in AlSi10Mg, an aluminum areas of engineering design, overall alloy, popularly used for light cost efficiency, marketability and weighting of functional parts by the vehicle performance. Team Stier automotive and aerospace industry. Racing from Ramaiah Institute of To account for tight tolerances, the Technology, Bangalore participated parts were subjected to post- in the event. They had incorporated processing activities such as heat 3D printed rear wheel hubs in their treatment and CNC machining. An EV. These were developed and excess stock of 0.5 mm was provided printed with low lead time and as the parts were subjected to finish weighed much lighter. . machining at amace solutions’ in- To achieve the objective of light house tool room facility. weighting, these parts were redesigned incorporating the The rear wheel hubs were subjected concepts of design for additive to several rounds of indoor as well as manufacturing (DfAM). The rear outdoor testing. It was also observed wheel hub was made hollow to that by incorporating honey comb accommodate honeycomb profiled lattice structures, the rear wheel lattice structures to bring about hubs were robust and displayed high weight reduction. These rear wheel strain tolerances. The 3D printed the hubs were usually machined from a rear wheel hubs increased the overall solid block of mild steel with a performance of the vehicle. Stier multiple setup changeover and were Racing aced the 5th edition of relatively heavier as compared to the Formula Green event and managed 3D printed rear wheel hubs. The need to bag many accolades in various Topology optimised, 3D printed for frequent setup changeover and categories. They finished 1st place in rear wheel hubs as printed (Top) specialised tools were eliminated, the vehicle endurance category and and after post processing thereby restricting the part were runners up in the overall vehicle (Bottom) development lead time to just 30 design category. They also finished days. Due to additive manufacturing, 5th in the Electric Vehicle category of a weight reduction of up to 42% was Formula Bharat competition. observed in the 3D printed rear wheel hubs in direct comparison to previous year's CNC machined rear wheel hubs. Advantages of using Additive The unsprung mass of the vehicle was Manufacturing (AM): also reduced by over 33%. This contributed to an improved vehicle Rapid product development. handling and the wheels of the vehicle stayed in contact with the Parts upto 42% lighter road even on a bumpy terrain as the Unsprung mass of vehicle 3D printed rear wheel hubs in loads acting on the shocks and action springs were reduced. reduced by 33% Part count reduction Improved vehicle handling Email: enquiries@am-ace.com High strain tolerance Website: www.am-ace.com Phone: +91 080 41828100 amace solutions Pvt. Ltd. 467-469, 12th cross, Peenya Industrial Area, Bangalore 560058 India
Enter the password to open this PDF file:
-
-
-
-
-
-
-
-
-
-
-
-