ArticleMaterials (Basel, Switzerland)2023
Topology Optimization of the Clutch Lever Manufactured by Additive Manufacturing.
Article in Materials (Basel, Switzerland), 2023. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Cited by 5 papers.
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Who cites it
5 citing papers in PubMed.
- Simulation and Experimental Study on Parameter Optimization for the Glass Molding Process of Automotive Panoramic Roofs.Materials (Basel, Switzerland) · 2026Article
- Artificial Intelligence in Metal Additive Manufacturing: Applications in Design, Process Modeling, Monitoring, and Quality Optimization.Materials (Basel, Switzerland) · 2026Review
- A Review of Simulation Tools Utilization for the Process of Laser Powder Bed Fusion.Materials (Basel, Switzerland) · 2025Review
- Weight Factor as a Parameter for Optimal Part Orientation in the L-PBF Printing Process Using Numerical Simulation.Materials (Basel, Switzerland) · 2024Article
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Authors and funding
10 authors.
Funding
Abstract
This article aims to review a redesign approach of a student racing car's clutch lever component, which was topologically optimized and manufactured by Additive Manufacturing (AM). Finite Element Method (FEM) analysis was conducted before and after a Topology Optimization (TO) process in order to achieve equivalent stiffness and the desired safety factor for the optimized part. The redesigned clutch lever was manufactured by using AM-Selective Laser Melting (SLM) and printed from powdered aluminum alloy AlSi10Mg. The final evaluation of the study deals with the experimental test and comparison of the redesigned clutch lever with the existing part which was used in the previous racing car. Using TO as a main redesign tool and AM brought significant changes to the optimized part, especially the following: reduced mass of the component (10%), increased stiffness, kept safety factor above the 3.0 value and ensured the more aesthetic design and a good surface quality. Moreover, using TO and AM gave the opportunity to consolidate multi-part assembly into a single component manufactured by one manufacturing process that reduced the production time. The experimental results justified the simulation results and proved that even though the applied load was almost 1.5× higher than the assumed one, the maximum von Mises stress on the component was still below the yield limit of 220 MPa.
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Registered trials
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