Structural re-design of engine components

Product design cycle Design Development Testing

Structural optimization

Product knowledge

Design freedom

Claudia Raffaldini

University of Parma

2/18

Structural re-design of engine components

Product design cycle Design Development Testing

Structural optimization

Kaya N., Karen I., Ozturk F., Re-design of a failed clutch fork using topology and shape optimization by the response surface method, Materials and Design 31, 2010.

Initial design

Optimized design

Failure

Max stress

Claudia Raffaldini

University of Parma

3/18

Structural re-design of engine components

Product design cycle Design Development Testing

Structural optimization

METHOD
ALTERNATOR BRACKET ENGINE SUPPORT

Two applications examined in thesis work:

Claudia Raffaldini

University of Parma

4/18

Numerical optimization method implemented by FEA software Altair HyperMesh (OptiStruct)

Kaya N., Karen I., Ozturk F., Re-design of a failed clutch fork using topology and shape optimization by the response surface method , Materials and Design 31, 2010. Geometry to be optimized Initial design volume Optimized geometry

Boundary conditions assigned to the FEM model of the component to be optimized

Extension of the initial design volume, according to the BCs

Selective material removal from the design volume, made by OptiStruct

Topological optimization:

material redistribution applying the SIMP Method (Solid Isotropic Material with Penalization):
density [0,1] finite element

Claudia Raffaldini

University of Parma

5/18

Widespread, useful for every optimization process

Input data - CAD/FEM model - Boundary/loading conditions - Experimental data Structural analysis of the component to be optimized

Setting up of the Design Region

Definition of initial geometry of the component

- Technological and manufacturing constraints - Hardware limitations

Settings of the optimization parameters

Analysis and modification

Analysis of results

First check: parameters quality

x x

Second check: initial geometry quality

Claudia Raffaldini University of Parma

6/18

Bracket used to connect the alternator to the engine The bracket is subjected to dynamic loading that could make the system oscillate at its resonance frequencies. To avoid this, the systems natural frequency of the normal mode I (RI) must be increased over an assigned treshold, possibly reducing the weight of the structure. This is the aim of the optimization.
Constraints
TARGET RI > 250 Hz
CONSTRAINT

Mass Initial mass

Material data (AlSi7)

Density
Elastic modulus

2,7 g/cm3
70000 MPa

Poissons ratio

0,3

Claudia Raffaldini

University of Parma

7/18

Bracket used to connect the alternator to the engine

TARGET RI > 250 Hz CONSTRAINT Mass Initial mass

Meshing

Original

Design Region

Optimized

Overall view of the optimization process made on the bracket:

Claudia Raffaldini

University of Parma

8/18

Modal analysis of the orginal design

Pre-processing

Simulation

Post-processing

Mode I 244 Hz

Mode II 435 Hz

Mode III 757 Hz

Deformed shapes for the first 3 normal modes

Claudia Raffaldini

University of Parma

9/18

Change in the geometry Setting up of the Design Region

Pre-processing

Simulation

Excluding the bolt seats

Post-processing

Density plot treshold = 0,3

Geometry reconstructed using the OSSmooth tool

RI = 273 Hz

Analysis of results Geometry reconstruction and modal analysis

OptiStruct automatically elimiminates FEs that dont have a structural function

Claudia Raffaldini

University of Parma

10/18

Structural verification

Uniform distribution of the Element Strain Energy (at a reasonable distance from the fixed nodes)

Outcome: design improvement Increase of the natural frequency of the normal mode I maintaining the initial mass

Original bracket

Optimized bracket

Mass (g) RI (Hz)

Claudia Raffaldini

702 244
University of Parma

702 273

Variation (%) 0 12
11/18

Test with different boundary conditions

Fixing nodes on the bolt holes Fixing nodes on the highlighted surfaces

Extending the Design Region

Optimization could sometimes generate unfeasible designs, requiring an iteration of the parameters setttings step in the overall process.
Claudia Raffaldini University of Parma

12/18

Engine support to fasten the engine base on the car frame The aim of the optimization is to minimize the stresses on the support, possibly reducing the weight and increasing its natural frequency of the normal mode I (RI) over an assigned treshold.
TARGETS
RI > 300 Hz Minimize the stresses

CONSTRAINT Mass Initial mass

Constraints

Material data (AlSi7)

Density Elastic modulus Poissons ratio Ultimate tensile strenght 2,6 g/cm3 77000 MPa 0,3 240 MPa

Yield strenght

180 MPa

Claudia Raffaldini

University of Parma

13/18

Iterative change of the Design Region to satisfy the second check on the initial geometry quality

Component to be optimized

Initial design 1st version

Initial design 2nd version

Initial design 3rd version

Loading

Rigid element (RBE2)

Loadcases: Bump (4g acceleration along y axis) + steering dx/sx

FX Fz FY

Claudia Raffaldini

University of Parma

14/18

Structural strength improvement (3rd version of the initial design)

Better stress distribution (at a reasonable distance from the fixed nodes)

Optimized Original support support

Claudia Raffaldini University of Parma

Original support 15/18

Influence of the settings of the parameters on the design variations

1 2 3

Sensitivity to optimization parameters:

1 2 3 4

- Design Region extension - Average element size - Draw direction - Minimum/maximum member size

Claudia Raffaldini

University of Parma

16/18

Outcome: design improvement

Original support

Optimized support

Variation (%) Mass (Kg) 2,82 2,95 5

RI (Hz)
Max Von Mises stress (MPa)

1382
81

1275
43

-8
-46

Significant stress reduction, despite little variations on mass and natural frequency of the first mode.

Claudia Raffaldini

University of Parma

17/18

Structural analysis of the component to be optimized

Method successfully applied to automotive components (alternator bracket, engine support) Stiffness targets met, satisfying mass requirements

Definition of initial geometry of the component

Settings of the optimization parameters

Faster optimization

Analysis and modification

Possible expansion:
Analysis of results

- Improvement of the Design Region setting up step

First check: parameters quality

- Fatigue analysis - Other components

Second check: initial geometry quality

- Other optimization algorithms

Claudia Raffaldini

- Software benchmarking

University of Parma

18/18