|Tipo di tesi||Tesi di laurea magistrale|
|Titolo||Studio e sviluppo tramite ottimizzazione topologica di pinza freno e portamozzo integrati per applicazione nel campo Motorsport|
|Titolo in inglese||Design by simulation of an integrated Upright and Brake Caliper for a Motorsport application|
|Struttura||Dipartimento di Ingegneria "Enzo Ferrari"|
|Corso di studi||Advanced Automotive Engineering (D.M.270/04)|
|Data inizio appello||2021-10-21|
|Disponibilità||Embargo di 3 anni|
|Data di rilascio||2024-10-21|
La tesi tratta lo studio di come strumenti quali l’ottimizzazione topologica e l’additive manufacturing possano essere impiegati nel campo del Motorsport, quando applicati ad un caso specifico riguardante l’integrazione di un portamozzo e annessa pinza freno in un unico componente. In particolare, se ne vuole studiare la fattibilità, vantaggi e svantaggi.
The target of this thesis is to study how Topology Optimization can be applied to a specific problem in the Motorsport environment. The goal is to establish if it is possible to integrate upright and brake caliper in one single component, producing it by Additive Manufacturing. An introductory chapter explains what Topology Optimization tools are, and which are the differences between Topology Optimization and Generative Shape Design. Are then present some comments about why Topology Optimization and Additive Manufacturing are important for the Motorsport environment, together with a description of the State of the Art regarding Uprights and Brake Calipers. Targets and requirement for the project are explained. The starting point is a real wheel assembly from an endurance car. KPI are identified. Weight reduction and integration of components are the main final targets. Follows a description of how the Topology Optimization tool has been used. The best caliper position has been found. An optimized final structure of the whole assembly has been generated. FEM studies are present, as well as studies focused on the realization of a final working and functional component. Evaluations regarding the brake disc and pads maintenance are reported. A qualitative thermal analysis of the whole assembly has been performed together with some evaluations about the weight reduction potential as function of the selected safety factor. In conclusion, for the studied problem, it is not possible to find a working solution that respects the imposed requirements. The high level of integration obtained thanks to the Topology Optimization tools forces to use Titanium alloys and Additive Manufacturing for the production of the component. Due to the low thermal conductivity of the material, thermal issues are present, which make the final part not feasible.