Numerical simulation of the design and selective laser melting process parameters for lightweight automobile wheels

Engineering Research Express, vol. 7, pp. 015423

Abstract

Abstract This study aims to explore lightweight and selective laser melting (SLM) process design for automobile wheels to improve the fuel economy and environmental sustainability of automobiles, which are studied using Altair Inspire and Simufact Additive software, respectively. First, a lightweight design is achieved while ensuring the safety factor through topology optimization and stress analysis. Then, the effects of the part placement, laser power, scanning speed, post-annealing temperature and time on the residual stress and distortion of the wheel are studied. The optimal printing method and process parameters that can minimize stress and distortion are obtained. The research results show that the weight of the automobile wheel after topology optimization is reduced by 7%, which reduces the material cost while ensuring the safety factor under the specified load. Through the simulation of the SLM process, it is found that adopting a horizontal placement method, reducing the laser power to 300 W, increasing the scanning speed to 3 m s−1, and increasing the annealing temperature to 500 °C can minimize the residual stress and strain of the wheel. Since the residual stress is basically stable when the annealing holding time is more than 0.3 h, 0.3 h should be the optimal holding time in consideration of saving post-processing time and shortening the production cycle.

Authors 6

1. Guangyuan Wang

   Changzhou University

   Affiliation as printed

   School of Mechanical Engineering and Rail Transit, Changzhou University, Changzhou, 213164, People’s Republic of China

2. Jiandong Wang Aachen Faculty of Mechanical Engineering

   RWTH Aachen University · Changzhou University

   Affiliation as printed

   Faculty of Mechanical Engineering, RWTH Aachen University, Aachen 52062, Germany

   Hua Lookeng Honors College, Changzhou University, Changzhou 213164, People’s Republic of China

3. Wangping Wu

   Changzhou University

   Affiliation as printed

   School of Mechanical Engineering and Rail Transit, Changzhou University, Changzhou, 213164, People’s Republic of China

4. Peng Cheng Jiang

   Changzhou University

   Affiliation as printed

   School of Mechanical Engineering and Rail Transit, Changzhou University, Changzhou, 213164, People’s Republic of China

5. Huihui Yang

   Shanghai Jiao Tong University

   Affiliation as printed

   School of Materials Science & Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

6. Ketao Yan

   Changzhou University

   Affiliation as printed

   School of Mechanical Engineering and Rail Transit, Changzhou University, Changzhou, 213164, People’s Republic of China

   The Engineering Research Center for CAD/CAM of Fujian Universities, Putian, Fujian 351100, People’s Republic of China