["Back To The Future" using Generative Design & Investment Casting]

8 hours ago, SteveCox3D said:

The above contributions to this thread by @geert_2 @laverda and @JohnInOttawa all make great points, especially in relation to the load cases that might be seen by this part either in normal, or even abnormal, use.

 

The part in this case study was produced from a Generative Design set-up using three different load cases acting on the pivot of the part.  None of those three load cases were applying a lateral load to the pivot because it was considered that the connecting part is constrained in such a way that it cannot transmit any lateral load, so the design synthesis has not had to take that into account.

 

One of the key things to realise about Generative Design is that it changes the role of the engineer/designer at the very start of the process. We are used to getting quickly into designing solutions for the part we need, but GD makes us think much more about the problem we are trying to solve.  That means spending more time at the beginning thinking through all of the possible loads, and directions of those loads, that the part will see during it's lifecycle.

 

That in itself can be a challenge because sometimes we don't know all of that information, which is why we tend to over-engineer parts, as John pointed out. To address that I've seen Generative Design being used in conjunction with load data that's been generated from real time, physical testing.  For instance instrumenting a car suspension set-up and then testing it to the absolute limits on a test track will give much more load data that can be input into the process.  That should generate a more robust solution.

 

GD is something that will make us think in a different way, and more deeply, about the things we design in order to fully take advantage of it's opportunities.  It's still very new and it's great to have discussions like this as we start to explore the way that we use it.  

7

Steve

Thank you for the clarification. It looks very promising. It would be interesting to see the difference if lateral loads were included. 

Steve

["Back To The Future" using Generative Design & Investment Casting]

Interesting thread and design. I am not a mechanical engineer although I have designed and sold a few products. I have to question the design at the pivot end though. It seems like the contact area to the pivot is much smaller and both longitudinally and around the circumference. It would have very little side to side strength to keep things aligned properly and I expect it to fail at the pivot. A side impact would easily cause an alignment issue if not a failure. I would think a further spaced contact area around the circumference and triangulation would increase the overall performance considerably without adding much material.

[UM3 FOR SALE WITH EXTRAS]

Price?