Additive manufacturing (AM) has had unprecedented growth as a manufacturing tool in many sectors. In recent years, more companies from various industries have used AM methods not only for creating prototypes but also for product mass production. AM can bring many advantages to the design optimization of complex-shaped parts. It can be used to develop products that would normally be fabricated with various conventional manufacturing methods such as casting, machining, etc., which would typically require more time, effort and cost. In combination with Topology Optimization (TO), AM can also be used to minimize the amount of material to create lightweight parts, which can be beneficial for many industrial products, especially in the aerospace application.
In this thesis, the benefits of TO and AM methods are explored by performing design optimization and analysis for an industrial gimbal mount in order to reduce fabrication time, cost and resources. The application of TO is to demonstrate how it can be used to reduce the weight and number of parts in an assembly, as well as demonstrate flexibility in shape design. Then AM is used to fabricate the parts with an engineering thermoplastic that has comparable material properties to the original design. The mechanical properties of the optimized designs are analyzed using Finite Element Analysis (FEA) to determine if they are comparable to the original design. As a result, the creation of two new gimbal mount configurations demonstrates design flexibility, as well as reduction of the weight and number of piece parts. They are also successfully fabricated using AM with an engineering thermoplastic. The FEA results of the new gimbal mount designs show that they are capable of maintaining the same loading conditions and mechanical properties as the original design. The results from this study can be used to optimize the design of other products in industry.
|Commitee:||Chae, Eun Jung, Schmitz, Adeline|
|School:||California State University, Long Beach|
|Department:||Mechanical and Aerospace Engineering|
|School Location:||United States -- California|
|Source:||MAI 82/3(E), Masters Abstracts International|
|Subjects:||Mechanical engineering, Materials science, Plastics|
|Keywords:||Additive manufacturing, Carbon fiber reinforcement, Gimbal, Lightweight design, Topology optimization|
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