Redesign of the Alfa Romeo Twin Spark CON ROD using Topology Optimization

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Function: The connecting rod transmits motion from the piston to the crankshaft. Reason for Design: A CON ROD for the Alfa Romeo was chosen because it is a functional part that needs improvement in mass and material usage. The current design uses forged steel and features an H-Beam structure, providing great strength. Design Tools Used: Redesign and topology optimization were done with Fusion360 Software. Topology Optimization Result: The new design maintains the H-Beam structure while reducing the weight of the CON ROD by 122 grams, achieving a more aesthetic form. Room for Improvement: Improving the number of produced machine parts could be made easier if those small replacement parts could be printed in workshops and garages. Relevance to proposed solutions in previous chapter: It demonstrates the possibilities of revolutionizing the spare parts industry by printing needed parts instead of mass producing them. This results in using less material, weighing less, and costing less to produce. 3D printable with metal, allowing for internal lattice structures. Problem Statement: Large amounts of used cars written off in Europe are shipped to Africa for a 'second life', creating a high demand for spare parts. Target Market: Automotive Aftermarket/Spare Parts Industries. Market Size: The global automotive aftermarket size was valued at USD 369.2 billion in 2018 and is anticipated to expand at a CAGR of 3.9% from 2019 to 2025. Current Solutions: Subtractive Manufacturing/CNC Milling, Casting and Molding, Forming and Shearing. Solution: Generative design, topological optimization, and the use of Metal and Composite additive manufacturing (3D Printing) of Automotive spare-parts make manufacturing cheaper, more functional, and resource-efficient by mass/weight reduction. Additive Manufacturing allows for distributed localized manufacturing of spare parts in many categories beyond the automotive after-market, ushering-in the 4th industrial revolution to Africa. School: Landmark University, Nigeria Course of Study: Mechanical Engineering