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Dottorando presso: Dipartimento di Ingegneria "Enzo Ferrari"

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2020 - Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints [Articolo su rivista]
Mantovani, Sara; Campo, Giuseppe Alessio; Ferrari, Andrea

In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is in the front area of the Body-in-White, between the left-hand-side shock-tower and the Cross Car Beam, and its task is to support the steering column. The dash under investigation is an asymmetric rib-web aluminium casting part. The influence of Additive Manufacturing constraints together with modal and stiffness targets is investigated in view of mass reduction. The constraints drive the topology result towards a feasible and fully self-supporting Additive Manufacturing solution. A simplified finite element model of the steering column and of the Body-in-White front area is presented, and the limiting assumption of isotropic material for Additive Manufacturing is discussed. The optimization problem is solved with a gradient-based method relying on the Solid Isotropic Material with Penalization and on the RAtional Material with Penalization algorithms, considering the overhang angle constraint with given build directions. Three metals are tested: steel, aluminium and magnesium alloys. Topology optimization results with and without overhang angle constraints are discussed and compared. The aluminium solution, preferred for its lesser weight, has been preliminarily redesigned following the optimization results. The new dash concept has been validated by finite element considering stiffness, modal responses, and buckling resistance targets. The proposed dash design weighs 721 g compared to the 1537 g of the reference dash, with a weight reduction of 53%, for the same structural targets.

2018 - Optimization methodology for automotive chassis design by truss frame: A preliminary investigation using the lattice approach [Relazione in Atti di Convegno]
Mantovani, Sara; Campo, Giuseppe Alessio; Ferrari, Andrea; Cavazzuti, Marco

The present paper investigates the application of optimization methodologies to vehicle chassis in view of an integrated and transdisciplinary vehicle design. A detailed sizing optimization in cascade to Topology Optimization (TO) for the design of automotive chassis is investigated. This approach is also known as lattice optimization. The TO is employed to find a coarse optimum chassis lay-out under linear elastic conditions. The second stage of the methodology converts into a truss frame the edges of the FE cells, including only the elements that remained above a certain density threshold after TO. The diameter of each truss is then optimized in view of chassis weight reduction while meeting a set of given design requirements, such as maximum stress and minimum size. Various tubular frame architectures for lightweight solutions are considered complying with different sets of constraints over different design spaces. Finally, the balance between the computational cost and the feasibility of the lattice solution is discussed in comparison to TO.