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Mee2016 Rapid Manufacturing Technologies Dr. Fathima Patham K, A2 Slot
Mee2016 Rapid Manufacturing Technologies Dr. Fathima Patham K, A2 Slot
PROJECT REPORT
DESIGN-ANALYSIS AND TOPOLOGY OPTIMIZATION OF A CAR SPOILER
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1. DESCRIPTION OF THE PROJECT
The spoiler assembly consists of the airfoil wing mounted on a support, secured with
bolts. Topology optimization can reduce weight as well as help to change the air flow
properties around the spoiler.
The spoiler parts can be 3D printed using ABS as material. A miniature scaled down
prototype is required to visualize the model. It will help to compare the strength of
different topologies. Thus, conventional casting could be replaced by 3D printing for
making car spoilers.
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2. GANTT CHART
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4. CFD ANALYSIS DESCRIPTION AND RESULTS
Computational Fluid Dynamics (CFD) Analysis, for a Car Spoiler is required for
justification of its role of disrupting the unfavourable airflow across a body of a
vehicle in motion, usually described as turbulence or drag.
Overall Flow
The above image helps in visualization of air flow over the spoiler. The input velocity
of air is assumed 50 m/s
Vortex Generation
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Due to unfavourable turbulence of air caused by highly speeding vehicle, vortex
generation takes place at the rear side of the car. These vortices are handled by a
spoiler as shown in figure.
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5. STRUCTURAL ANALYSIS (TOPOLOGY OPTIMIZATION)
RESULT TABLE:
Material Stress (MPa) Weight (before Weight (After
Optimization) (gms) Optimization) (gms)
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6. SLICING ON CURA
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Single Layer Generation
Layer Addition
RESULT TABLE:
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7. CONCLUSION:
From the above observations, it is clear that increasing the nozzle diameter reduces
time. Decreasing layer thickness increases time. And material-wise time required
decreases in the order ABS > PLA > PC. By choosing optimal Layer Thickness and Nozzle
Diameter, we can produce faster prints in higher resolution.
The Results of Stress Analysis of spoiler, showed that PLA was the strongest material,
but it also was the heaviest one. On the other hand, ABS was the lightest one and its
stress values are under the safety limit.
Therefore, we can conclude that the ABS is optimal material for producing spoilers by
casting ABS plastic with various admixtures, typically granular fillers, which introduce
stiffness to this inexpensive material.
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8. REFERENCES:
https://en.wikipedia.org/wiki/Spoiler_(car)
https://physics.stackexchange.com/questions/140969/benefits-of-rear-spoiler-in-cars
https://www.physlink.com/education/askexperts/ae496.cfm
https://www.yourmechanic.com/article/4-essential-things-to-know-about-your-car-s-spoiler
http://ijsrd.com/Article.php?manuscript=IJSRDV5I30954
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