Optimized Build Orientation and Laser Scanning Strategies for Reducing Thermal Residual Stress in Topology-Optimized Automotive Components

Abstract

This study investigates the reduction in thermal residual stress during the powder bed fusion (PBF) process in a non-standardized shape generated by topology optimization method in lightweight automotive part of brake caliper. While the caliper of the braking system for reducing the CO2 consumption in vehicle systems undergoes a redesign to increased strength and reduced weight, challenges arise due to biased melting area ratios in the topologically optimized design, causing the thermal deformation. To address this, our research proposes an efficient PBF scan strategy aimed at minimizing anisotropy and residual stress—a critical consideration for successful manufacturing. The effectiveness of the laser scan strategy is validated through testing on a brake dynamometer, following the JASO C406 test procedure, an authorized standard for commercial brake calipers. Furthermore, a comparative analysis between the conventional product and the proposed brake caliper highlights superior performance, particularly under lightweight conditions. This comprehensive approach contributes valuable insights to the field, offering a potential solution for overcoming manufacturing challenges associated with topologically optimized designs in automotive components.

Keywords

• additive manufacturing (AM)
• powder bed fusion (PBF)
• topology optimization
• brake caliper