ANALYSIS OF 3D PRINTED VS CONVENTIONALLY MACHINED FSAE UPRIGHTS

With the advancement in technologies for additive manufacturing, it is now possible to create complex parts which once required hours of machining and produced considerable amount of scrap. Upright is an important component of a car as it connects the wheel assembly to suspension components. It has to tolerate force due to braking, steering and bump and it also holds brake caliper. Reducing unsprung mass is a major aim to build any race car as it reduces the inertia and helps to keep tires in contact with the road. Upright being considered an unsprung component makes for a perfect object for analysis. Aim of this report is to compare and analyse the CAD model designed for conventional machining and 3D printing, find the difference in mass and compare the stresses generated due to forces mentioned above. The work from this project will result in a lighter, more complex upright without compromising on the strength.