Análise da substituição da carcaça usinada por carcaça fundida da caixa de redução de um veículo Baja SAE

Abstract

This study analyzed the feasibility of replacing a machined reduction gearbox housing with a cast housing made of AlSi9 aluminum alloy for application in a Baja SAE vehicle. The research included the geometric adaptation of the component for gravity sand casting, followed by mold filling and solidification simulations using Altair Inspire Cast software, which enabled the optimization of the feeding system and the reduction of casting defects. Subsequently, structural simulations were performed in Altair Inspire to compare the mechanical behavior of the machined and cast housings by evaluating stress distribution, deformation, and safety factors. Physical prototypes were manufactured to validate the simulation results through dimensional inspection, mechanical testing, and metallographic analysis. The results demonstrated that the cast housing achieved structural performance comparable to that of the machined housing while maintaining the mechanical integrity required for the application. In addition, the casting process provided lower manufacturing costs and greater potential for serial production. Therefore, it was concluded that casting with AlSi9 aluminum alloy is a technically viable alternative for manufacturing reduction gearbox housings for Baja SAE vehicles, highlighting the importance of integrating computational simulation, mechanical design, and manufacturing processes in the development of engineering components. [resumo fornecido pelo autor]