This study deals with the structural integrity of a co-axial octocopter cargo drone. Most unstable states in progress of various flight missions of the cargo drone are considered to be derived from take-off and landing operations. In order to evaluate the structural integrity of these states, three-dimensional FE (finite element) simulation using whole frame assembled with structural members and components is performed, and then the effective stress level and deflection degree are investigated. Also, topology optimization is adopted to improve the locally concentrated stress and large deflection around front and rear sections of the motor-support side member. From topology optimization, it is ensured that the shape and location of plate support have to be modified for improving the stress level and the deflection degree. Based on the optimized and modified feature, FE simulation is re-performed. Consequently, it is confirmed that the effective stress and the deflection are reduced to about 26.67% and 19.15% around the side member, respectively.
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With advancements in the 3D printing technology, many industrial sectors are transitioning from traditional production methods, such as cutting processing, and casting, to utilizing 3D printers for manufacturing. For instance, in the automotive industry, the production of vehicle upright knuckle parts typically involves casting followed by machining processes, such as turning and milling, to achieve dimensional accuracy. However, this approach is associated with high processing costs and longer lead times. This study focuses on the production of vehicle upright knuckle parts using a selective laser melting (SLM)-type 3D printer, with SUS 630 as the material. To evaluate the feasibility of utilizing this method in industrial vehicles, this study conducts static and modal analyses, along with topology optimization. Additionally, experimental test drives are performed with the parts installed in KSAE BAJA vehicles, and modal frequency experiments are conducted. The objective of these analyses and experiments is to assess the performance, reliability, and applicability of utilizing SLM-based 3D printing for manufacturing vehicle upright knuckle parts by optimizing the design through topology optimization and evaluating the results through experiments and analysis.
Electric kickboards provide personal mobility with a simple structure and easy operation. With these advantages, the number of users is increasing annually. However, as the number of users of electric kickboards increases, related accidents are also increasing. To prevent accidents, this study proposes the topological optimization of an electric kickboard connecting part to improve structural strength during a front collision. The results confirmed that as the volume fraction increased, the structure connecting the board and the bottom of the handle support changed to a toroidal shape, thereby lowering the maximum stress and improving the uniformity of the stress distribution. In addition, the topological optimization was safer than the connecting parts of two typical electric kickboards sold in the Korean market. These findings can contribute to improving the safety and optimizing the design direction of electric kickboards.
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Owing to recent advances in additive manufacturing technology, design for additive manufacturing (DfAM) has been used to overcome design limitations due to constraints in traditional manufacturing processes. In this study, we applied DfAM technology to design lightweight and consolidated vacuum grippers for inspection equipment. We proposed a consolidated design to reduce manufacturing time and costs, which previously encompassed assembling eleven components. Topology optimization was used to reduce part weight while maintaining structural rigidity and safety, and two optimization models were designed: two-piece and one-piece models. Based on these optimized geometries, the internal vacuum paths were designed in a curved shape to enhance adsorption characteristics. Numerical simulations were conducted to evaluate the structural performance and flow characteristics of the initial design and the two optimization models. The pressure drop of the one-piece model, which was the best design, was reduced to 1/8 of the initial design and the structural safety factor was predicted to be 6.37. This final design was then additively manufactured by a digital light processing type 3D printer and the weight of the resulting parts was reduced from 12.94 to 2.08 g. Experimental observation found that the additively manufactured vacuum gripper showed enhanced absorption performance compared to the initial design.
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The purpose of this study was to design a sledge frame for para ice hockey in which an athlete sits and plays on a sledge. A sledge comprises a bucket, a blade carrier, and a frame. A sledge frame is usually fabricated by welding a number of pipes, and thus its structural safety is degenerated at the welded joints. In this study, the sledge frame was redesigned using the principle of DfAM (Design for Additive Manufacturing), to reduce the frame weight as well as to have sufficient structural safety. As an application of DfAM, the part consolidation was performed for six joints from which the number of welding spots was reduced to 56% (From 16 to 9). Among the resulting four consolidated joints, topology optimization was performed for three joints to reduce their weight while maintaining higher structural stiffness and safety. As a result, the structural stiffness and safety of the joints improved remarkably, and the resulting frame weight was reduced by 20% (From 1.66 to 1.34 kg). This weight reduction with structural enhancement is expected to improve athletes’ performance and safety in para ice hockey games.
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The sanding device support bracket is part of the axle box and is one of the railway vehicles parts that must withstand extremely harsh environments. Conventional welded structure type brackets were cracked at welds during operation, requiring design changes. To minimize harsh environments and manufacturing errors, this review was conducted from the design stage, and design changes were made through several trial and error. In this paper, the optimal design was derived by performing topology optimization on the model designed and manufactured through trial and error and applied to the actual vehicle. The comparison of the existing model with the empirically designed model confirmed the improvement of the optimal design using the topology optimization. The optimized design was verified by the analysis and the vibration test of IEC 61373 was satisfied. The test parts based on the optimal design were applied to the actual vehicle and the performance was verified. In the optimum design process, the shape and material as well as the weight analysis were performed and finally the brackets were designed to be light in weight and improved in strength.
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To secure the precision forming capability of a press while reducing its production and transport costs, the development of stiff and lightweight frame is important. In this study, the topology and multi-objective structural optimization problem of a frame structure was introduced with an effort to develop highly stiff and lightweight frame for a mechanical press with 300 ton capacity. First, a design space model was constructed to derive a new frame structure different from the existing one for topology optimization. Using the design of experiments and the structural analysis model of the frame structure improved based on the topology optimization result, the multi-objective optimization problem was established with loop stiffness and mass of frame as objectives and the steel plate thickness as design variable. The review on Pareto optimum solutions of the multi-objective optimization problem revealed the fact that this optimization method could significantly contribute to the high stiffness and lightweight frame structure for a mechanical press.
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In this paper, the topology optimization method was used to describe the lightweight design of link structures for an amphibious boat. Topology optimization was used to determine the optimum density distribution of the structure. The analysis revealed that the link structures for amphibious boat can be reduced up to 31 percent by weight without altering the design of the connected and supported parts. The structural integrity of the proposed lightweight link structures was evaluated via topology optimization and verified by finite element analysis and static test. The structural integrity of lightweight link structures was found to meet the design requirements. The running stability of amphibious boat with lightweight link structures was verified via ground and water driving tests.
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Optimal Design and Experimental Validation of the Rib Structure of a Manufacturing Machine Bed Using Topology Optimization Ji-Sang Hwang, Sung-Jae Kim, Jeong-Hyun Yoon, Chul-Hoon Sung Journal of the Korean Society of Manufacturing Technology Engineers.2023; 32(6): 374. CrossRef
Study on the Optimal Design of Column Rib Structure of Horizontal Machine Tool Using Topology Optimization Technique Ji-Sang Hwang, Sung-Jae Kim, Chul-Hoon Sung Journal of the Korean Society of Manufacturing Technology Engineers.2023; 32(1): 1. CrossRef
Optimization Design of Student KSAE BAJA Knuckle Using SLM 3D Printer Young Woo Im, Geon Taek Kim, Hyeon Sang Shin, Kang Min Kim, Bu Hyun Shin, Jong Won Lee, Jinsung Rho Journal of the Korean Society for Precision Engineering.2023; 40(9): 719. CrossRef
Designing the internal reinforcements of a sailing boat using a topology optimization approach Antonio Mancuso, Antonio Saporito, Davide Tumino Applied Ocean Research.2022; 129: 103384. CrossRef
A Study on Injection Mold Design Using Topology Optimization Mi-Jin Kim, Jae-Hyuk Choi, Gyeng-Yun Baek Journal of the Korean Society of Manufacturing Process Engineers.2022; 21(4): 100. CrossRef
Lightweight Design of a Vacuum Gripper for Inspection Equipment Using Topology Optimization Euddeum Cha, Tae-Young Kim, Taeho Ha, Keun Park Journal of the Korean Society for Precision Engineering.2021; 38(9): 683. CrossRef
Optimal Design for Strength Improvement of Support Bracket for Sanding Device of Railway Vehicle Using Topology Optimization Yonho Cho, Woohyuck Yoon Journal of the Korean Society for Precision Engineering.2020; 37(4): 263. CrossRef
Lightweight Design of a Sledge Frame for Para Ice Hockey Using Design for Additive Manufacturing Eun-Ji Oh, Ju-Hye Lee, Jae-Eun Kim, Keun Park Journal of the Korean Society for Precision Engineering.2020; 37(6): 407. CrossRef
This study reviews the assumption that the lightweight design of commercial vehicles is significant from the aspect of the anticipated fuel consumption and environmental regulations that are consequently applicable to those vehicles. Generally speaking, it is noted that among the numerous trailer components, a stub axle, which is designed to independently operate as an integral part of trailer’s suspension, can play an important role in increasing the shipping capacity of a box trailer. For this reason, because each stub axle is comparatively a heavy unit in itself, and a total of six stub axles are mounted in a box trailer, the lightweight design of a stub-axle is noted as an essential factor to reduce the whole weight of a trailer. For a finite element analysis, an original CAD model is modified through removing a chamber, airbag, axle drum, bearing and pivot on a vehicle. In addition, the loading conditions are imposed considering three extreme driving conditions and the effects are studied when in the event of review of a fully loaded in a box trailer. A topology optimization is conducted to determine a lightweight design for minimizing compliance under these boundary conditions.
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Toward structure optimization for the mobile vehicle system based on multiconstraints Xin Zhao, Jie Li, Shunli Sun, Chongyang Han, Wenbo Zhu, Zhaokai He, Luxin Tang, Weibin Wu, Jiehao Li Robotic Intelligence and Automation.2023; 43(1): 75. CrossRef
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Optimal Design for Strength Improvement of Support Bracket for Sanding Device of Railway Vehicle Using Topology Optimization Yonho Cho, Woohyuck Yoon Journal of the Korean Society for Precision Engineering.2020; 37(4): 263. CrossRef
In this paper, topology optimization of a main roller for Multi-wire saws is conducted for the purpose of reducing mass of the main roller. Modal analysis is carried out to evaluate whether the resonance could have occurred, or not. The pressure from the cutting wires are modelled mathematically. Topology optimization analysis with the pressure model developed is conducted to derive optimal solution of the sectional shape of the roller. As a result, the cross section of the main roller manifests as an arch shape. The mass of the final optimal model is reduced by 14%, while the deflection and natural frequencies of the roller is same as those of the base model.
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Research on High-Speed Vibration and Structure Optimization of Multiwire Sawing Machine Zhikui Dong, Ao Liang, Long Chang, Shang Wu, Binfeng Hou Applied Sciences.2023; 13(17): 9889. CrossRef
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Study on the Bearing Arrangement of Multi-wire Saw Equipment Using Spring Elements Hye Ryang Park, Jun Young Lee, Hong Jae Yim, Jay Il Jeong Transactions of the Korean Society for Noise and Vibration Engineering.2019; 29(4): 488. CrossRef
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