Your browser does not support Javascript
  The NIST Manufacturing Extension Program for Kentucky

Advantage KY News

UofL Rapid Prototyping CenterL Automotive Case Study

UofL Rapid Prototyping Center: Automotive Case Study

The design freedom of metal additive manufacturing can be used to reduce the mass of structural parts while maintaining mechanical performance. The UofL Rapid Prototyping Center (RPC) recently completed a feasibility study for a major automotive supplier. 

Current part

“TWI Graphic

The current part, fabricated by casting, serves to clamp a bearing assembly in a truck drivetrain and is subject to significant and complex loads – tensile, compressive and torsional. The challenge was to reduce the weight of the steel part while meeting performance requirements.

Analysis

“Analysis Graphic

Working with the company’s engineering staff a structural analysis of the current part identified peak stress locations, critical dimensional constraints and the available design volume. The part needed to align with bolt holes in a larger structure and must not interfere with other parts nearby.

Design

“Design Graphic 1

RPC engineers created several design concepts, removing metal in some locations and redistributing stress more uniformly through the remaining material. Some designs were simple – hollow regions within the current geometry.  Other were more complex.  The best of these provided 30% mass reduction. None could be fabricated using traditional manufacturing methods

 Prototype fabrication“Prototype Graphic

A design with internal hollow regions was selected for fabrication using RPC EOS M290 laser powder bed fusion system. While matching the external shape of the current part it offered 15% weight reduction.  Use of this design – or a more complex option – in future production will depend on a full feasibility study.

Contact information:

Website: louisville.edu/rpc

Email: tim.gornet@louisville.edu

Phone: 502-852-0714

This article regards processes and equipment that are produced by partners with Advantage Kentucky Alliance.  Please contact us for more information, or with any questions.  Contact AKA’s Marketing Specialist (Kurt Felten) at (270) 745-3370.


Categories
Latest Headlines
Blue-Collar Workers Are Now Scarcer than White-Collar Workers

While it's not news to manufacturing companies that workers, of any collar, are hard to find, a new report from the Conference Board found that it is harder to find blue-collar workers than white-collar workers...

New Composite Advances Lignin as a Renewable 3D Printing Material

Scientists at the Department of Energy’s Oak Ridge National Laboratory have created a recipe for a renewable 3D printing feedstock that could spur a profitable new use for an intractable biorefinery byproduct: lignin...

Warning to Robots: Humans Perform 72% of Manufacturing Tasks

(IW – Staff: 11-16-18) Despite the widespread fear, and more than enough reports, proclaiming that robots will be taking over the factory floor, it seems that time has not yet come. Humans still perform 72% of manufacturing tasks...

Featured Articles

No Featured Articles for this category

Note: documents in Portable Document Format (PDF) require Adobe Acrobat Reader 5.0 or higher to view,
download Adobe Acrobat Reader.

Note: documents in Excel format (XLS) require Microsoft Viewer,
download excel.

Note: documents in Word format (DOC) require Microsoft Viewer,
download word.

Note: documents in Powerpoint format (PPT) require Microsoft Viewer,
download powerpoint.

Note: documents in Quicktime Movie format [MOV] require Apple Quicktime,
download quicktime.