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Simulação de processos para fabrico aditivo metálico
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Abstract(s)
O presente relatório descreve o projeto desenvolvido no âmbito da unidade curricular Projeto, integrado no curso de Mestrado em Engenharia Mecânica – Produção Industrial (MEM – PI).
No mundo do ciclismo de alta competição, é cada vez mais importante otimizar a aerodinâmica e reduzir o peso dos componentes integrantes da bicicleta, de modo a melhorar o desempenho dos ciclistas, realçando que uma diferença de 100 gramas, faz diferença ao fim de 5 horas de esforço. Este projeto foca-se na otimização topológica de um destes componentes.
O objetivo principal deste projeto é otimizar uma pedaleira (alumínio 5086) de uma bicicleta para reduzir a sua massa, mas mantendo a sua integridade mecânica. O objetivo secundário deste projeto é obter um componente otimizado que seja a junção do braço, da aranha e do prato da pedaleira, transformando assim os três componentes num só.
Foi feita a otimização com recurso ao software Siemens NX num modelo muito aproximado ao de uma pedaleira já existente, tendo sido feita uma alteração, de modo a tapar com material uma porção da pedaleira, dando assim ao software mais material com que possa trabalhar e otimizar de uma maneira mais eficiente e livre.
O componente otimizado obtido apresenta uma redução na massa do conjunto da pedaleira em cerca de 120 gramas face à pedaleira original, no entanto mais testes deveriam ser feitos no modelo, tais como estudos aerodinâmicos e estudos de viabilidade no que diz às condições de fabricação da peça, e também deveriam ser feitas otimizações, quando assim for possível, que tenham em conta o eixo de orientação da impressão, de modo a prevenir zonas com suportes desnecessários e voids internos, quando fabricada por fabrico aditivo.
This report describes the project developed as part of the course unit “Project”, integrated into the Master’s in Mechanical Engineering – Industrial Production (MME – IP). In the world of high-competition cycling, it is increasingly important to optimize aerodynamics and reduce the weight of the bike's components to improve cyclists' performance, highlighting that a difference of 100 grams can make a difference after 5 hours of effort. This project focuses on the topology optimization of one of these components. The main objective of this project is to optimize a crankset (made of aluminum 5086) for a bicycle to reduce its weight while maintaining its mechanical integrity. The secondary objective is for the optimized component to combine the crank arm, spider, and chainring into one, thus transforming the three components into a single one. The optimization was performed using NX software on a model very similar to an existing crankset. A modification was made to cover part of the crankset with material, thus providing the software with more material to work with and optimize more efficiently and freely. The optimized component achieved a mass reduction of about 120 grams compared to the original crankset. However, more tests should be conducted on the model, such as aerodynamic studies and feasibility studies regarding manufacturing conditions. Additionally, further optimizations should be made, where possible, considering the orientation axis for 3D printing to prevent areas with unnecessary building supports and internal voids when manufactured via additive manufacturing.
This report describes the project developed as part of the course unit “Project”, integrated into the Master’s in Mechanical Engineering – Industrial Production (MME – IP). In the world of high-competition cycling, it is increasingly important to optimize aerodynamics and reduce the weight of the bike's components to improve cyclists' performance, highlighting that a difference of 100 grams can make a difference after 5 hours of effort. This project focuses on the topology optimization of one of these components. The main objective of this project is to optimize a crankset (made of aluminum 5086) for a bicycle to reduce its weight while maintaining its mechanical integrity. The secondary objective is for the optimized component to combine the crank arm, spider, and chainring into one, thus transforming the three components into a single one. The optimization was performed using NX software on a model very similar to an existing crankset. A modification was made to cover part of the crankset with material, thus providing the software with more material to work with and optimize more efficiently and freely. The optimized component achieved a mass reduction of about 120 grams compared to the original crankset. However, more tests should be conducted on the model, such as aerodynamic studies and feasibility studies regarding manufacturing conditions. Additionally, further optimizations should be made, where possible, considering the orientation axis for 3D printing to prevent areas with unnecessary building supports and internal voids when manufactured via additive manufacturing.
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Keywords
Otimização topológica Fabrico aditivo Ciclismo NX