Topological optimization of the Formula Student bell crank

Abstract

This paper focuses on the topological optimization of the Formula Student bell crank. Modern trends in designing are weight reduction, and due to this, also reduction of fuel consumption. Topological optimization allows modification of the shape of the component in respect to the strength demand and the boundary conditions of component loading.

The topological optimization software with respect to computational methods is used. This software accomplishes several interactions and evaluates the optimal one. Topologically optimized component manufacturing is usually done by 3D printing. In this article, the authors follow the development of a topologically optimized bell crank, choice of printing material (metallic powder), and description of its design development and geometrical shape smoothing step by step - from the very first design to the final topologically optimized model. The design also takes into consideration the production technology by metallic powder 3D printing and post-processing, which cannot be realized without CNC machining and clamping jigs.