Topology optimization and additive manufacturing of a ratchet handle

Prananda, Aufaa Audi (2024) Topology optimization and additive manufacturing of a ratchet handle. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This research evaluates a Ratchet handle, which is a commonly found ratchet in the market. The study seeks to redesigned the ratchet to minimize the weight while satisfy the same target design envelope and meeting the technical requirements, and by using the Topology Optimization (TO) technique. The objectives of this research are; to redesign and optimize the 3/8” Ratchet topology with varying design space volume between 30%-70%, compare and recommend the various design based on the analysis using Altair Inspire and also optimize the build orientation, and also compare and recommend the material for the selected design based on the analysis using Altair Inspire. The methodology has two sections, the first section deals with pre-analysis and topology optimization, where the load found by calculating the force needed to tighten an M10 bolt, and then the topology optimization process was performed in order to get topology-optimized design with optimal von Mises stress, displacement, mass, and factor of safety. The second section contains the material comparation between the original material of the ratchet which is chromium-vanadium, chromiummolybdenum, and steel (4142). Then proceed to the build orientation optimization in Autodesk Netfabb to obtain the minimum amount of support structure during additive manufacturing process. In the result, the 708 N was found as the load that applied to the ratchet handle, the result also selected the 50% design space volume retention as the best topology-optimized model amongst the seven (7) iterations conducted, while the material that have been compared, resulting chromium-molybdenum as a slightly better choice as a material. Finally, for the additive manufacturing process, the results selected Rank 1 as the best build orientation amongst the thirteen. In conclusion, the research selected a 50% design space volume retention to reduce the mass of a topology-optimized ratchet from 0.1937 kg to 0.1807 kg, which was a 19.57% weight saving.

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