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  • Mee2016 Rapid Manufacturing Technologies Dr. Fathima Patham K, A2 Slot

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    Rishitej rao Kulakarni
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    This project report details the design, analysis, and 3D printing of a car spoiler. Computational fluid dynamics (CFD) analysis was conducted to analyze air flow over the spoiler. Topology optimization reduced the spoiler's weight while maintaining structural integrity. ABS plastic was found to be the optimal material after analyzing the stress values of ABS, PLA, and PC materials. Slicing software was used to determine optimal printing parameters like layer thickness and nozzle diameter to minimize printing time. In conclusion, ABS plastic can be 3D printed to produce lightweight yet strong car spoilers.

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    CFD Spoiler

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    This project report details the design, analysis, and 3D printing of a car spoiler. Computational fluid dynamics (CFD) analysis was conducted to analyze air flow over the spoiler. Topology optimization reduced the spoiler's weight while maintaining structural integrity. ABS plastic was found to be the optimal material after analyzing the stress values of ABS, PLA, and PC materials. Slicing software was used to determine optimal printing parameters like layer thickness and nozzle diameter to minimize printing time. In conclusion, ABS plastic can be 3D printed to produce lightweight yet strong car spoilers.

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    41 views10 pages

    Mee2016 Rapid Manufacturing Technologies Dr. Fathima Patham K, A2 Slot

    Uploaded by

    Rishitej rao Kulakarni
    This project report details the design, analysis, and 3D printing of a car spoiler. Computational fluid dynamics (CFD) analysis was conducted to analyze air flow over the spoiler. Topology optimization reduced the spoiler's weight while maintaining structural integrity. ABS plastic was found to be the optimal material after analyzing the stress values of ABS, PLA, and PC materials. Slicing software was used to determine optimal printing parameters like layer thickness and nozzle diameter to minimize printing time. In conclusion, ABS plastic can be 3D printed to produce lightweight yet strong car spoilers.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    of 10

    MEE2016 RAPID MANUFACTURING TECHNOLOGIES

    Dr. Fathima Patham K, A2 Slot

    PROJECT REPORT
    DESIGN-ANALYSIS AND TOPOLOGY OPTIMIZATION OF A CAR SPOILER

    Group Name: 3D_Spoilers


    Name Registration No.
    Rahul Rakesh Goenka 16BME0960
    Advaith Venkataraman 16BPI0037

    1
    1. DESCRIPTION OF THE PROJECT

    A spoiler is an automotive aerodynamic device whose intended design function is to


    'spoil' unfavourable air movement across a body of a vehicle in motion, usually
    described as turbulence or drag. Spoilers are often fitted to race and high-
    performance sports cars, although they have become common on passenger
    vehicles as well.

    Spoilers are usually made of lightweight polymer-based materials, including: ABS


    plastic, Fiberglass, Silicone, Carbon-Fibre. Most original equipment
    manufacturers produce spoilers by casting ABS plastic with various admixtures,
    typically granular fillers, which introduce stiffness to this inexpensive material.
    Frailness is a main disadvantage of plastic, which increases with product age and is
    caused by the evaporation of volatile phenols.

    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.

    2
    2. GANTT CHART

    3. DESIGN / DRAWING OF THE PRODUCT

    3
    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

    4
    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.

    Iso Surface (Wing centre profile)

    Visualization of flow over the centre of the wing

    Iso Surface (leg + wing profile)

    Visualization of flow over the support/leg of the spoiler

    5
    5. STRUCTURAL ANALYSIS (TOPOLOGY OPTIMIZATION)

    Structural Analysis is performed in order to compare the strength of different


    materials (ABS, PLA, PC) and also to optimize the geometry of the wing by removing
    unnecessary structure and hence reducing weight of the component.

    Visualization of stress generation on the spoiler.

    Optimized structure (reduced weight)

    RESULT TABLE:
    Material Stress (MPa) Weight (before Weight (After
    Optimization) (gms) Optimization) (gms)

    ABS 3.15 681 635


    PLA 2.81 803 749
    PC 2.97 771 719

    6
    6. SLICING ON CURA

    Solid View of Spoiler in Cura

    Layer View of Spoiler in Cura (With Supports)

    Layer View Without Supports

    7
    Single Layer Generation

    Layer Addition

    RESULT TABLE:

    Processing Parameters Output


    Layer Thickness Nozzle Diameter Material Time
    0.06 mm 0.35 mm PLA 18 h 13 min
    0.1 mm 0.3 mm PLA 13 h 23 min
    0.1 mm 0.4 mm PLA 10 h 30 min
    0.1 mm 0.4 mm PC 9 h 51 min
    0.1 mm 0.3 mm ABS 19 h 54 min
    0.15 mm 0.35 mm ABS 11 h 25 min

    8
    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.

    9
    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

    10

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