Como citar APA:
Zumba-Novay, E., Merizalde-Salas, A. (2023)
Optimization of the manufacturing process by 3D printing of the glass
lift handle in Chevrolet Aveo Family. Repique, 5(1), 100-125
Vol. 5 Núm. 1
Enero – Junio 2023
e-ISSN: 2550-6676
pp 100-125
Optimization of the manufacturing process by 3D printing of the
glass lift handle in Chevrolet Aveo Family
Ember Zumba-Novay
*
Alex Merizalde-Salas
*
Abstract
The objective of this research is to provide an alternative solution
through 3D printing of the handle of the glass elevator of the
Chevrolet Aveo vehicle, which was simulated and evaluated in
Inspire software where its mechanical properties were verified prior
to printing. The 3D printing process was performed, and the
weights of the original and optimized handle were compared with
Inspire and Simsolid software, respectively. In addition, the
displacements, safety factor, and deformation analysis of the
original and optimized handle were compared. The study was
based on the multi-criteria and COPRAS methods, to compare
materials selected as the best alternatives to replace the original
(PLA, PC and PVC). The results showed that the most suitable
material to replace the original is PLA because it has excellent
mechanical and physical characteristics. Through Inspire it was
possible to change the original design of the handle, obtaining an
optimized proposal with a 2.7% lower weight, in addition, the 3D
* Escuela Superior Politecnica de Chimborazo, Ent. 1 ESPOCH, Panamerican Highway
South km 1 ½, 060155, Riobamba, Ecuador. ezumba@espoch.edu.ec
https://orcid.org/0000-0002-2121-8418
* Carlos Cisneros Technological Institute, La Paz 07-56 & Mexico, 060110, Riobamba,
Ecuador. alex.merizalde@itscarloscisneros.edu.ec, https://orcid.org/0000-0002-0469-
5079
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printing time is reduced by 8.3% compared to the original model.
With the present study it can be mentioned that the PLA alternative
material is ideal to replace the original ABC-PC, and the benefits of
the analysis contribute to have an alternative to industrial
production in the world of vehicles.
Keywords:
Optimization, 3D printing, simulation, mechanical
analysis, vehicle handle.
Optimización del proceso de fabricación mediante impresión 3D
de la manilla del ascensor de cristal del Chevrolet Aveo Family
Resumen
El presente trabajo de investigación tiene como objetivo brindar una
alternativa de solución a través de la impresión 3D de la manija del
elevador de vidrio del vehículo Chevrolet Aveo, la cual fue simulada
y evaluada en el software Inspire donde se verificó sus propiedades
mecánicas previo a la impresión. Se realizó el proceso de impresión
3D y se compararon los pesos del mango original y optimizado con
el software Inspire y Simsolid, respectivamente. Además, se
compararon los análisis de desplazamientos, factor de seguridad y
deformación del mango original y optimizado. El estudio se basó en
los métodos multicriterio y COPRAS, para comparar materiales
seleccionados como las mejores alternativas para reemplazar el
original (PLA, PC y PVC). Los resultados mostraron que el material
más adecuado para reemplazar el original es el PLA debido a que
presenta excelentes características mecánicas y físicas. A través de
Inspire se logró cambiar el diseño original del mango, obteniendo
una propuesta optimizada con un 2,7% menos de peso, además, el
tiempo de impresión 3D se reduce en un 8,3% respecto al modelo
original. Con el presente estudio se puede mencionar que el material
alternativo PLA es ideal para reemplazar el ABC-PC original, y los
Ember Zumba-Novay, Alex Merizalde-Salas
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beneficios del análisis contribuyen a tener una alternativa de
producción industrial en el mundo de los vehículos.
Palabras Clave:
Optimización, impresión 3D, simulación, análisis
mecánico, manejo de vehículos.
Received :
03-09-2022
Approved:
22-11-2022
INTRODUCTION
The 3D printing process, also known as additive manufacturing, has
been investigated for over 20 years with applications in aerospace,
automotive, architecture and medical treatment (Goh et al. 2017).
The most used printing technologies for polymer resin include ink
jet printing (Choi et al. 2017), fused deposition modeling (Ngo et
al. 2018), digital light printing (Mu et al. 2017), stereolithographic
printing (Yan & Gu 1996), and laser-assisted laminated object
fabrication (Parandoush et al. 2017).
Nowadays, the industrial sector is closely related to technology,
where additive manufacturing, 3D printing process, and computer
aided design and manufacturing [CAD] play an essential role in the
computer systems (Li et al. 2020), which involves the design and
manufacture of products. In advanced engineering, CAD has
revolutionized the 21st century as an important tool to help solve
problems in the industrial sector efficiently and with reliable results
(Li et al. 2020). Analysis and simulation are important when mass
producing products in the industrial sector, as it helps to reduce
environmental pollution. Today, the automotive sector has become
one of the most important industries of the modern era; its status
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lies in the social and economic effect it causes (Pereira y Romero
2017).
To meet the quality standards and challenges in modern
manufacturing processes, industries must select the best available
design, process planning, machine tool, materials, welding process,
inspection system, etc., as the choice of the right alternative is
affected by various attributes, the decision-making process is not
an easy task. In recent years, there have been many changes and
innovations in manufacturing (Makhesana 2015). Many of the latest
technologies, such as robotics, flexible manufacturing systems,
rapid prototyping, etc., have been developed by today's
manufacturing (Ding et al. 2004). Decision-makers in the industry
must consider various characteristics of the alternative, such as
economics, aesthetics, serviceability, technical details, etc., and,
based on this, it is possible to select the appropriate alternative
(Hwang 2012).
The multi-criteria method and the COPRAS method used in the
automotive industry are analytical tools of great utility and potential
in engineering processes (Roy 1996). This interweaving of multi-
criteria and systemic approaches can be addressed both at the
conceptual level and at the operational level of concrete actions
(Abu et al. 2021). The multi-criteria method is an assessment and
operational decision support approach for dealing with complex
problems that offer high uncertainty, conflicting objectives,
different forms of data and information, multiple interests and
perspectives, and an evolution of complex systems (Kumar et al.
2017). While the COPRAS method selects the best decision
alternatives considering ideal and worst-case solutions, in a step-
by-step ranking and evaluation of the alternatives in terms of their
importance and degree of usefulness (Chérrez-Troya et al. 2018).
The use of both methods helps to identify the materials that present
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better properties for 3D designs and printing, taking into account
that there is a wide range of materials that can be used in many
areas of the automotive industry (Haruna, Shafiq, & Montasir 2021).
In Ecuador, the Chevrolet Aveo Family is one of the common
vehicles sold in the market. The handle of the glass elevator of this
vehicle is constructed of plastic material and the cost in the
domestic market is around 12 dollars. However, this plastic material
is not resistant enough to impacts or any type of damage. The
handles of the glass elevators are frequently changed after a certain
period of time, principally due to wear on the inside of the coupling
presenting damage, breakdown or failure at the time of fulfilling its
function of displacement (Zumba 2021).
Today, composite materials provide weight reduction and thermal
and chemical resistance to weathering, which has driven the
development of new thermoplastic materials for the automotive
industry, both in interior and exterior components. This provides a
new style to vehicle parts (Patil, Patel, & Purohit 2017). Selected
materials have been used as the best alternatives to replace the
original among them we have PLA, PC and PVC (Rahman & Brazel
2004).
Due to the high variability of manufacturing parameters, the
integration of simulation tools such as finite element analysis with
fused filament manufacturing is particularly attractive for designing
3D printed products and analyzing the mechanics of complex
geometries (Ali, Batai, & Sarbassov 2019).
This article analyzes the simulation of 3D printing that is performed
in the Inspire software because printing 3D designs is talking about
the process of manufacturing and creating parts and objects, i.e.
using the three-dimensional x, y, z plane where these variables are
the height, length and width from a digital model of the design that
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is built using computer software and then will be printed
(Bordignon, Iglesias, & Hahn 2018).
Depending on the industry or business in which the 3D printer is
going to be used, the material will vary, since each one has different
properties that will determine the final appearance of the solid
(Chango 2021). A large portion of printers use a filament of
thermoplastic material, which during printing comes out of the
extruder melted and then hardens as it cools (Mazzanti, Malagutti,
& Mollica 2019). The most common are ABS and PLA, which is why
they are the most used for the present article. PLA is a thermoplastic
material of natural origin; it has good characteristics. Printing with
this material is faster, although the solids obtained do not present
much resistance, as ABS vs PLA can be analyzed it can be
mentioned that for our analysis we could select the ABS material for
presenting better properties as far as it has to do with hardness and
resistance (Mazzanti et al. 2019).
Therefore, the main objective of this study is to optimize the 3D
printing manufacturing process of the handle of the Chevrolet Aveo
Family vehicle glass lifter for the improvement of mechanical
properties. Specifically, the 3D design of the glass lifter of the
Chevrolet Aveo Family vehicle was carried out by using Inspire
software for the simulation of the mechanical behavior with the PLA
alternative material. The 3D printing process and the comparison of
the weights between the original handle and the optimized handle
are shown, as well as their displacement, safety factor and
deformation analysis between both handles.
METODOLOGY
The methodology visualizes according to Table 1 the properties of
the most appropriate materials for printing the handle, according
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to reports of several authors (Santos & Paganotti 2019), where the
PLA material was used in this article.
Table 1.
Physical, mechanical, and thermal properties of materials
for elevator handle
Properties
Characteristics
PC-
ABS
PC
PLA
PVC
Cost
4 Kg-1
10
7.5
8.0
6.9
Physics
Density [g cc-1]
1.1
1.0
1.3
1.3
MFI [gr 10min-1]
10
11
23
20
Mechanics
Tensile strength (MPa)
45
20
20
30
Elongation at break
(%)
100
110
6
210
Elastic modulus in
tension (GPa)
2.3
2.1
3.5
2.87
Bending resistance
(MPa)
80
34
80
84
Impact resistance
(J/M)
587
600
600
800
Thermal
Vicat Temperature
(°C)
129
103
60
92
With the list of materials and their referential properties, we
proceeded to perform the multi-criteria method and the COPRAS
method to select the material that will be the alternative to 3D print
the handle of the Chevrolet Aveo's window lift.
Multi-criteria method
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To apply the multi-criteria method, different steps were proposed
and established to improve the decision-making process to select
the best and most appropriate material to allow the design and
printing of the Chevrolet Aveo's window lift handle, as shown in Fig.
1.
Figuere 1.
Model for decision making based on the multi-criteria
method
COPRAS Method
The COPRAS method helps to select the best values that guide to
the ideal results. In order to apply the COPRAS method correctly,
the following steps should be followed as suggested by (Chérrez-
Troya et al. 2018), as shown in Fig. 2.
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Figure 2.
Steps to apply the COPRAS method
According to Fig. 2, the first step is developed from the decision
matrix, from which the same normalized matrix of the COPRAS
method was used. In step 2, the normalized decision matrix was
defined, based on equation 1.
(1)
Where,
is the normalized decision matrix, aij is the value of each
criterion In the third step, equation 2 is applied:
(2)
Where,
is the standardized weight matrix,
is the weights of
each criterion, and
is the normalized matrix values.
In step 4, weight will be given to each criterion according to the
property compared to the property to be achieved, with equations
3 and 4.
(3)
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(4)
Where,
is the negative normalized weight,
is the sum of the
weights of each positive criterion, and S-i is the sum of the weights
of each negative criterion normalized matrix values In the step 5, a
degree of satisfaction is sought for each alternative applying the
equation 5.
(5)
Where,
is the relative priority.
In step 6, it is proposed to compare the qualities of each alternative
material looking for the most efficient by percentage applying the
equation 6.
(6)
Where,
is the performance,
is the máximum priority.
In the final step, 7. The one material with the highest value is
considered as the best option. These methods (Multicriteria and
COPRAS) have been considered for the correct selection of the
material according to the characteristics of the original material to
fulfill the function for which it was designed.
Simulation and parameters of 3D Printing with PLA material
To perform the simulation of the Chevrolet Aveo Family vehicle's
glass lift handle, 3D modeling was performed based on the
selection of the winning material according to the COPRAS
method, based on the best physical, and mechanical, properties of
the PVC, PLA, and PC materials. The 3D simulation of the glass lift
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handle of the Chevrolet Aveo Family vehicle was performed using
Cura Software, version 4.6.1.
According to Qamar et al. (2022), there is a better tensile
mechanical behavior of 3D printed elements when they have 100%
filler. Based on Camargo et al. (2019) refers that 3D printed parts
subjected to bending loads give better results with 100% infill and
honeycomb type. Considering these considerations, a dynamic
printing quality was established with which layers of 0.16mm height
and 0.84 mm thickness were generated from the initial and final
layers of the handle, as well as a printing speed of 60mm/s. Once
the filling parameters were defined, the printing simulation was
executed.
Considering the use of the same printing parameters previously
established, the possibility of carrying out the 3D printing of the
original design handle using PLA was considered, thus starting with
the importation and positioning of the geometries. To establish a
comparison between the printing processes of the original and
optimized handle, the same printing parameters such as speed,
percentage, and type of filling, among others, were used. Once all
the parameters were established, the simulation of the 3D printing
process was executed, where the supports for all the surfaces were
generated and the software calculates the printing time.
The handle optimization process was carried out in Inspire software,
starting with the elimination of the internal reinforcements of the
original model and increasing the amount of material in the middle
section of the handle in such a way that the software can eliminate
material until an adequate design is obtained for the loads to which
the geometry is exposed. Once all the optimization parameters on
the geometry of the handle were defined, the execution was carried
out under the default parameters established by the software
prioritizing 30% of the use of the available material. Once the
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optimization process is finished, the ideal amount of material
calculated by the software is important for the element to withstand
the loads to which it is exposed.
Once the geometry of the optimized handle was obtained, the
structural analysis was carried out considering the same conditions
regarding loads and movement restrictions described above,
however, for this analysis it is necessary to specify PLA as
construction material; the software library does not contain this
material, so to define it was necessary to enter properties such as
the modulus of elasticity, density, and Poisson's coefficient. After
the material was created, it was added to the library and for the
analysis it was assigned to the whole handle.
RESULTS
In Fig. 3(a), the upper part of the optimized proposal with the new
design is observed once the 3D printing of the element is finished.
The other part of the 3D printing process is shown in Fig. 3(b),
where the handle and the base of the handle are observed, in
addition to the supports that were generated.
Figure 3.
(a) Top view of 3D printed optimized middle part and (b)
3D printed handle and base
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After removing the brackets on all the printed elements and
assembling the components, the proposed optimized 3D printed
Chevrolet Aveo family vehicle window lift handle was obtained. Fig.
4a shows the original design handle 3D printed using PLA and Fig.
4b shows the optimized 3D printed handle.
Figure 4.
(a) Top view of the 3D printed optimized middle part and
(b) 3D printed optimized handle
The Cura software was able to establish the differences between
the printing of the original design handle and the optimized
proposal, analyzed under the same printing parameters, only
differing in its geometry. Table 2 summarizes the main differences,
where once the simulation of the 3D printing process was executed,
the Cura software took a printing time of 7 hours and 26 minutes
using 17.96 m of PLA material.
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Table 2.
Differences between original and optimized handle 3D
printing
Design
Printing
material
Printing time
Quantity of
material used
Original
PLA
7 hours and 26
minutes
17.96 m
Optimized
PLA
6 hours 49
minutes
17.84 m
Weights between original and optimized design handle
Using SimSolid software, the weight of the original and the
optimized design handle was 22.2 gr and 21.6 gr, respectively. The
optimization process resulted in a 0.6 g reduction in the weight of
the element.
Displacements in the original handle
The applied load of 70 kg generates a maximum deformation in the
handle of 21.77 mm in the handle grip area, in Fig. 5, these results
and the distribution of the values along the entire geometry can be
observed.
Figure 5.
Displacement at the original handle at 70kg load
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114
On the other hand, figure 6a shows the maximum displacement that
occurs in the handle when the horizontal pulling force is applied,
where it shows a value of 7 mm, while Fig. 6b shows a value of 4
mm when the load is applied vertically, in both cases it is presented
in the section where the load is applied.
Figure 6.
Maximum (a) displacement in the handle horizontally and
(b) vertically
Safety factor on the original handle
The stresses produced by the 70 kg load result in the safety
coefficients shown in figure 7, where the lowest value obtained is
0.14; therefore, the areas painted in red show excessive structural
resistance stresses.
Figure 7.
Safety coefficient for 70 kg load on the original handle
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From the structural analysis it is obtained that the minimum safety
factor for the simulation considering the vertical and horizontal
pulling load is 1.1, however, in Fig. 8a it can be observed that when
the load is applied horizontally, the ends of the central section of
the handle are the most exposed parts, while in Fig. 8b when the
vertical load is applied, the reinforcements of the central section are
the elements that support the greatest stress. The minimum value
of the safety factor occurs in the reinforcements at the base of the
handle.
Figure 8.
Safety factor in original handle
Optimized handle displacements
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The analysis with 70kg produces a deformation in the handle of
21.43 mm at the grip which is the place where the force is applied
and as it approaches the support base these values decrease as
shown in Fig. 9.
Figure 9.
Deformation in the optimized handle under the 70 kg load
When applying the horizontal load the optimized handle undergoes
a displacement of 7.63 mm, as shown in Fig. 10a, while in Fig. 10b,
when applying the vertical load, a maximum deformation of 4.14
mm is recorded.
Figure 10.
Displacement in the (a) horizontal and (b) vertical the
optimized handle
Optimized handle safety factor
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The minimum value of the safety factor generated by the 70 kg load
on the handle is 0.14 and these are present in the entire optimized
section and support, as shown in Fig. 11.
Figure 11
. Safety factor in the optimized handle for the 70kg load.
Fig. 12a shows the distribution of the values of the safety factor in
the optimized handle when applying the horizontal pulling load, the
lowest value is 1.3 and is in the upper part at the height of the grip
area, the elements that remain in tension are the ends of the middle
section of the handle. On the other hand, Fig. 12b, shows the
results of the safety factor in the handle when applying the vertical
load, it is observed that greater stresses are produced at the base
of the handle, thus generating a minimum safety factor of 1.06 and
slight stresses in the middle area of the handle that are supported
by the internal reinforcements.
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Figure 12.
(a) Distribution of the values of the safety factor in the
optimized handle (b) when applying the load
Deformation analysis between the original and optimized handles
Because of the excessive application of the 70 kg load, a plastic
deformation of the elements occurs, which is reflected in the values
shown in Table 3.
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Table 3.
Deformation under 70 kg load
Analysis
Maximum deformation (mm)
Force 70 kg
Critical zone
Original handle
21.77
Base
Original handle
21.43
Base
The deformation produced in the models because of the average
applied pulling loads is shown in Table 4, as can be seen from the
values, there is no significant change in the analyzed results.
Table 4.
Deformation in the original and optimized handles
(maximum deformation)
Analysis
Horizontal
force
Vertical force
Original handle
7.7
4.2
Optimized handle
7.6
4.1
CONCLUSIONS
The application of the multi-criteria method and the Copra’s
method facilitates the selection of the winning alternative material
that can replace the original material, resulting in a maximum value
of 100% to PLA for the manufacture of the handle of the window lift
for the Chevrolet Aveo Family vehicle. PLA is a biodegradable
material that presents excellent mechanical, physical and thermal
properties to be able to develop the manufacture of automotive
accessories, allowing fast and immediate alternatives in the national
markets.
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The optimization process resulted in a change in the geometric
design of the original handle, distributing in a better way the
amount of material and the reinforcements in the middle part of the
handle, allowing to support in a more efficient way the loads that
act on the element.
It was verified that the weight of the optimized handle is 2.3% lower
compared to the original design, this value represents a significant
advance considering that this type of elements used in the
automotive area constitute a wide field of study with the purpose
of lightening the weight of vehicles and improving their efficiency.
It was determined that the mechanical behavior of the optimized
handle under horizontal load, which generates traction, produces a
3.3% reduction in the stresses generated in comparison with the
original handle, while the opposite happens with vertical load, since
the stress increases by 17.9%; however, its location changes
towards the base of the handle where the stress is distributed in a
better way since this area has more reinforcements. It was
determined that the deformation decreases 1.2% in the optimized
handle, a value that represents an imperceptible variation.
In general terms, the analysis of the mechanical behavior of both
handles is similar; however, the added value of the proposal
generated in this work is the process of obtaining it through 3D
printing, since this manufacturing method allows customizing the
element according to the user's taste if the geometry developed
here is respected.
The appropriate use of engineering software allows to have
simulations close to reality, reducing manufacturing costs that were
used for the analysis, through Autodesk Inventor the design of the
handle of the glass elevator of the Chevrolet Aveo family vehicle
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was built, through the Inspire software is optimized and simulations
are performed for their respective analysis.
After performing the respective evaluation analysis with the
different methods mentioned above in this research, it can be
indicated that they all have potential properties that would allow
them to be used in industrial manufacturing, for this reason it is
important to perform future research with PC and PVC materials.
After manufacturing by 3D printing, the surface finish of the auto
part can be improved through sanding, puttying, and painting, thus
obtaining a product of excellent quality.
Based on the research, it is also recommended that a comparison
be made between the plastic injection molding manufacturing
process and the additive manufacturing process for the
manufacture of auto parts that do not require mass production.
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