HBD’s metal Additive Manufacturing elevates Tongji University’s TJURacing car design
September 12, 2024
Metal Additive Manufacturing machine maker Shanghai Hanbang 3D Tech Co, Ltd (HBD) reports that it has partnered with the TJURacing team, from China’s Tongji University, to develop a range of metal additively manufactured chassis and powertrain components for the team’s 2024 Formula Student Automotive Engineering (FSAE) competition race car.
The partnership between HBD and the TJURacing team, now in its second year, aims to address the challenges of designing and manufacturing a race car that meets the requirements of speed, strength, and compliance with strict competition regulations.
Traditional machining methods can face limitations in producing parts with the required precision and complexity, explains HBD. For example, the exhaust manifold, a key component in the vehicle’s powertrain, features an irregular surface and complex internal structures that were difficult to manufacture. By turning to HBD’s metal Additive Manufacturing, the team was able to produce a part that not only fits perfectly with the engine’s exhaust system, but was durable under high-pressure conditions.
In addition to the exhaust manifold, the team also applied HBD’s technology to other critical components such as the aluminium alloy steering knuckles and brake and acceleration rails. These components required precise sliding mechanisms and pin positioning, which were challenging to achieve with traditional manufacturing techniques. HBD’s metal Additive Manufacturing allowed the team to meet these design needs effectively, resulting in components that reportedly functioned seamlessly within the car’s overall design.
Another key component, the clutch lever, required a design that provided specific ergonomics and tactile feedback for the driver. Using Additive Manufacturing, the team produced a handle that met these ergonomic requirements and provided the necessary feedback during operation, enhancing the overall driving experience.
Testing
The success of the new components has been confirmed through extensive testing, demonstrating the practical benefits of integrating metal Additive Manufacturing into the team’s design and manufacturing processes. The high level of manufacturing precision ensured that even components with minimal tolerance deviations were easy to install and functioned as intended.
The material properties of the additively manufactured parts, including their resistance to high temperatures and pressures, were confirmed during testing, contributing to the race car’s overall durability and performance. Additionally, the lightweight nature of the titanium alloy parts used in the exhaust system helped reduce the vehicle’s weight, improve exhaust flow, and reduce backpressure.
What’s next
While the TJURacing team remains focused on continuous improvement, the support provided by HBD’s metal Additive Manufacturing technology reportedly played a significant role in advancing their car’s performance. The precision and quality of the additively manufactured components have allowed the team to explore more complex and optimised designs in an effort to push the boundaries of what’s possible in FSAE car development.
One of the year’s most anticipated events is the FSAE Japan 2024 competition, which will take place in Aichi Prefecture, Japan. The TJURacing team is one of only two Chinese teams granted entry. The competition is scheduled to take place September 9-14.
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