Topology Optimization Utilizing Density-Based Approach for Additive Manufactured Components: A Case Study of an Automotive Brake Caliper

The recent developments in additive manufacturing technologies lead to rapid production of fully functional customized parts with high geometric complexity and without the limitations of the traditional manufacturing methods, such as machining. Hence, in the last decade, the structural optimization of the existing products has gained increased scientific interest, especially in form of topology optimization. In the current chapter, the basic principles and the main methods of the topology optimization processes are described and analyzed coupled with a novel case study presentation of the topology optimization procedure of a brake caliper designed for additive manufacturing (DfAM). More specifically, the case study focused on the topology optimization of a brake caliper for the automotive industry, in order to reduce the overall weight and enhance the performance of the vehicle. Firstly, an original design of the brake caliper was studied via finite element analyses (FEA) under realistic static loads and the need for the topology optimization of the part was pointed out. Through the topology optimization process, the maximum mass reduction from the original design was achieved by holding the mechanical response of the part on the desired levels, i.e., maintaining the factor of safety above one. To conclude, the topologically optimized design of the brake had a weight of almost 2173 gr compared to the original design of 3195 gr achieving a mass reduction of 32%. It is worth mentioning that the factor of safety for the final design was calculated at 1.325.