Prediction and Optimization of Sustainable Production Processes for Automotive Components

Abstract

This paper includes the study of power train components of an All-Terrain Vehicle. The research aims to optimize the designs and reduce the weight by iterating on different materials and designs using Finite Element Analysis. It also includes various studies of their manufacturing processes and compares them with additive manufacturing techniques to check the increase in sustainability and the reduction in material wastage. Reducing material wastage and reducing the carbon footprint using additive manufacturing techniques is the main target of the paper. In this work, a gearbox has been designed for a vehicle as an example. The loads have been calculated and the materials also have been selected for the gears and the casing. The materials selected are the materials that are commonly used in the present industry. Finite Element Analysis and optimization have been done to reduce the weight while maintaining a good safety factor at the same time. Sustainability analysis will further be done to compare the amount of carbon footprint by the two processes. From this study, the paper aims to create a process for machine design that takes sustainability, material usage, and carbon footprint into account apart from conventional considerations like weight, strength, size, etc. This will help promote a sustainable environment which is an increasing need. Finally, the work aims to create a process through an example of how to create a sustainable designing and manufacturing process.