Structural Optimization of the “Tulip” Housing of a Tripod Type Inner CV Joint for the power transmission in a Formula SAE sport car

This research project aims at fully exploiting the potential of Additive Manufacturing technologies in the redesign of a key component of the power transmission of the Formula SAE car of the University of Padova. The most suitable geometrical configuration is identified through Genesis GTAM®, which is a topological optimizer with advanced algorithms for several manufacturing processes (including Additive Manufacturing). The geometry is then refined by performing a standard optimization, where the modeFRONTIER optimizer drives a parametrized FEA model created in ANSYS Workbench. Mass minimisation, while maintaining both static and fatigue strength, are the objective and the constraints, respectively. Further to the design phase, the component is additively manufactured. Finally, the prototype will be tested at the test bench at the University of Padova by applying the spectrum loading acquired on the track.