Presentation on the design of an optimized control arm utilizing 3D printed sand molds.

1. OPTIMIZED CASTING
USING ADDITIVE
MANUFACTURING
Dakota Morgan

2. OBJECTIVES
• Reduce manufacture time for suspension
components of the Iowa State University
Solar Car
• Fabricate a proof of concept part
• Optional
• Reduce cost from current option
• Reduce weight from current option
• Increase strength from current option

3. MODELING
• Autodesk Inventor
• Current control arm in
use is well optimized for
machining
• Goal is to design a
control arm which is
improved from the
machined option and
able to be cast

4. MODELING
• Design began with the idea of maximum
strength
• Rapidly redesigned and optimized the
control arm
• Next step was to optimize the design for
manufacture (casting and machining)
• Constraints are strength, weight, and
safety considerations

5. FINITE ELEMENT ANALYSIS (FEA)
• Using Autodesk Inventor allowed rapid design
to FEA testing
• Simulation parameters were held identical to
6061-T6 machined control arms
• Worst case scenario in all simulations was a
1000 lb force on the upright bearing
• This simulates locking the breaks at full speed
CONTROL ARM CURRENTLY IN USE (6061-t6) CAST CONTROL ARM DESIGN (A356-T5)

6. MAGMASOFT
• Used MagmaSoft to
simulate molten
aluminum flow
through a mold
• Checked for issues
with flow, porosity,
inclusions, hot spots,
etc. before
prototyping
Video Courtesy Nicholas Bouska UNI Techworks Casting Center

7. MOLD DESIGN
• Casting molds are typically designed
around the limitations of the process
• Parts must have drafted edges
• Complex features are difficult to retain
• Must be thick enough to retain heat
during a pour

8. MOLD DESIGN
• Benefits of using 3D printing with casting
• No need to design draft into the part
for mold creation
• No waste of material during
fabrication
• Ideal heat distribution during pour
Pouring Cup
Sprue
Gate
Riser
Vent
Mold

9. PRINTING

10. CASTING
•Aluminum A356
•Heated with Induction Furnace
•Pouring temperatures
•Pour 1: 1330°F
•Pour 2: 1360°F

11. CASTING

12. HEAT TREATMENT
• Recipe for A356-T5/T6
• Cast with quench at 800°F
• HRH: 87.75
• Nine hours at 1000°F followed by 125°F quench
• HRH: 82.23
• Nineteen Hours at 300°F, allowed to air cool to 75°F
• HRH: 102.5
• Current Cast Control Arm
• HRH 114.75

13. RESULTS

14. OBJECTIVES
• Reduce manufacture time for suspension
components of the Iowa State University
Solar Car
• Fabricate a proof of concept part
• Optional
• Reduce cost from current option
• Reduce weight from current option
• Increase strength from current option

15. SPECIAL THANKS
• Dr. Emmanuel Agba
• Sponsor Professor
• Jerry Thiel: Director – Rapid Casting Technologies (UNI)
• Donation and printing of molds used for the project
• Nick Bouska: Technician – Rapid Casting Technologies (UNI)
• Assistance with flow design and MagmaSoft testing
• John Howell: Teaching Lab Coordinator
• Assistance with heat treatment recipe and casting
• Craig Severson: Teaching Lab Coordinator
• Assistance with casting