Master’s thesis is focused on a design of front uprights for Dragon 8 racing car of TU Brno Racing Formula Student team. This thesis follows up the bachelor’s thesis called “Race Car Front Wheel Carrier Design”. Discussion about team’s recent upright and component designs is followed by a model creation with use of topology optimization. Final geometry is simulated in FEA software. Design of the upright is then compared to the previous designs and also to its substitute produced with milling machining process.

The master thesis deals with the design of geometry of plates of the injection molding unit using the FEM tool Topological Optimization. The reason for this is to reduce the weight of these components, which is beneficial in the transport and assembly of the injection molding machine. However, the final models of geometry of plates must meet certain requirements in terms of the limit state of deformation, the limit state to the critical value of the equivalent stress. This condition involves both limit state of elasticity and limit state of fatigue. Computational modeling and also Topological Optimization are performed in ANSYS Workbench.

This thesis deals vith the design of welding torch holder using topology optimization and lattice structure. The objective of this thesis is gaining knowledge about topology optimization in different software and aplication of methods to that part. Conclusion of this thesis is about production design and economic evaluation.

Indiana University-Purdue University Indianapolis (IUPUI) / Traumatic Brain Injuries (TBI) are one of the most apprehensive issues today. In recent years a lot of research has been done for reducing the risk of TBI, but no concrete solution exists yet. Helmets are one of the protective devices that are used to prevent human beings from mild TBI. For many years some kind of foam has been used in helmets for energy absorption. But, in recent years non-traditional solutions other than foam are being explored by different groups. Focus of this thesis is to develop a completely new concept of energy absorption for helmet liner by diverting the impact forces in radial directions normal to the direction of impact. This work presents a new design of an advanced layered composite (ALC) for energy dissipation through action of a 3D array of compliant mechanisms. The ALC works by diverting incoming forces in multiple radial directions and also has design provisions for reducing rotational forces. Design of compliant mechanism is optimized using multi-material topology optimization algorithm considering rigid and flexible material phases together with void. The design proposed here needs to be manufactured using the advanced polyjet printing additive manufacturing process. A general and parametric design procedure is explained which can be used to produce variants of the designs for different impact conditions and different applications. Performance of the designed ALC is examined through a benchmark example in which a comparison is made between the ALC and the traditional liner foam. An impact test is carried out in this benchmark example using dynamic Finite Element Analysis in LS DYNA. The comparison parameters under consideration are gradualness of energy absorption and peak linear force transmitted from the ALC to the body in contact with it. The design in this article is done particularly for the use in sports helmets. However, the ALC may find applications in other energy absorbing structures such as vehicle crashworthy components and protective gears. The ultimate goal of this research is to provide a novel design of energy absorbing structure which reduces the risk of head injury when the helmet is worn.

Indiana University-Purdue University Indianapolis (IUPUI) / Lattice structures have seen increasing use in several industries including automotive, aerospace, and construction. Lattice structures are lightweight and can achieve a wide range of mechanical behaviors through their inherent cellular design. Moreover, the unit cells of lattice structures can easily be meshed and conformed to a wide variety of volumes. Compliant mechanism make suitable micro-structures for units cells in lattice structures that are designed for impact energy absorption. The flexibility of compliant mechanisms allows for energy dissipation via straining of the members and also mitigates the effects of impact direction uncertainties. Density-based topology optimization methods can be used to synthesize compliant mechanisms. To aid with this task, a proposed optimization tool, coded in MATLAB, is created. The program is built on a modular structure and allows for the easy addition of new algorithms and objective functions beyond what is developed in this study. An adjacent investigation is also performed to determine the dependencies and trends of mechanical and geometric advantages of compliant mechanisms. The implications of such are discussed. The result of this study is a compliant mechanism lattice structure for impact energy absorption. The performance of this structure is analyzed through the application of it in a football helmet. Two types of unit cell compliant mechanisms are synthesized and assembled into three liner configurations. Helmet liners are further developed through a series of ballistic impact analysis simulations to determine the best lattice structure configuration and mechanism rubber hardness. The final liner is compared with a traditional expanded polypropylene foam liner to appraise the protection capabilities of the proposed lattice structure.

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京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第18469号 / 工博第3905号 / 新制||工||1599(附属図書館) / 31347 / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 西脇 眞二, 教授 椹木 哲夫, 教授 松原 厚 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第19681号 / 工博第4136号 / 新制||工||1638(附属図書館) / 32717 / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 西脇 眞二, 教授 稲室 隆二, 教授 松原 厚 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

付記する学位プログラム名: デザイン学大学院連携プログラム / 京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第21099号 / 工博第4463号 / 新制||工||1693(附属図書館) / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 西脇 眞二, 教授 椹木 哲夫, 教授 松原 厚 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第21754号 / 工博第4571号 / 新制||工||1712(附属図書館) / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 西脇 眞二, 教授 北村 隆行, 教授 小森 雅晴 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM