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NEW METHODOLOGY FOR DESIGNING DIRECT-LASER-SINTERED MOTORCYCLE FRAME BASED ON COMBINATION OF TOPOLOGY OPTIMIZATION AND LATTICE IMPLEMENTATION
Authors: THANH BINH CAO & SLAWOMIR KEDZIORA
Number of views: 431
The use of direct laser sintering (DLS) has become more attractive recently since it offers a promising tool in
fabricating complex components rapidly. Particularly, the technique is seen more powerful when it is combined with
computer-aid design and computational optimization. In spite of knowledge increment in the above areas presently,
design method for sophisticated structures towards DLS is still far from being fully exploited. Therefore, this paper was
issued to investigate a novel methodology of design, developed by combining topology optimization and lattice-beam
implementation, for a blend-solid-lattice frame of a motorcycle. From the obtained results, it was recognized that the
as-built tubular hybrid structure demonstrated comparable values of first resonant frequency and mass with respected to
those of the original. Additionally, it was found that stiffness of the generated structures depended strongly on locations
where lattice was substituted. In particular, less stressed frame’s components were evidenced as appropriate regions for the
substitution. The achieved results also revealed estimated buckling load factors, being circa 18 times higher than applied
bumping loads acted on the tubular-lattice structure. Finally, equivalent stress predicted in static analyses confirmed all
designs working safely in nominated conditions. Based on these achievements, it is believed that the new method worked
quite acceptably in designing direct-laser-sintered motorcycle frame, and it is very promising to further develop the method
as well as extend it into different complex direct-laser-sintered elements designed for future applications.