Kostenstelle 04.10.

2005, Kostenstelle, 1

Welcome !

Dr. Rainer Meyer-Pruessner

OTC 05 September 27th – 28th, 2005

Optimization Technology Troy, MI, USA
Conference

Significant Weight Reduction by Using

Topology Optimization in Volkswagen
Design Development
with emphasis on engine design

27. September 2005 Topology Optimization at 2

Volkswagen

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Agenda
o How we started …

o Example: design development of an engine bracket

o Example: design development of a heat shield

o Course of the design process

o Selection of optimized components
o Shape/ Topology Optimization of an engine sector

o Areas of application
o Consequences of weight reduction
o Summary

27. September 2005 Topology Optimization at 3

Volkswagen

How we started …
Engine bracket for T4

952 g 733 g

New design adapted to load condition, i.e. material is removed

where not contributing to load carrying capacity
April 1997

27. September 2005 Topology Optimization at 4

Volkswagen

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Topology Optimization of an engine bracket

Z
Y X
Principle configuration:
Engine bearing – engine bracket

Design objective:
engine bracket
as light as possible -
made from aluminium

27. September 2005 Topology Optimization at 5

Volkswagen

Topology Optimization of an engine bracket

Load impact Design space

Forces applied:
- on longitudinal axis
- on vertical axis
Bolt-on points for engine block - for assembly

27. September 2005 Topology Optimization at 6

Volkswagen

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Topology Optimization of an engine bracket

Design proposal: Construction according to design proposal.

Best material distribution under impact of all Suitability for casting must be taken
forces & including manufacturing constraints, into account.
i.e. demolding direction

27. September 2005 Topology Optimization at 7

Volkswagen

Topology Optimization of an engine bracket

Computer
simulation of
casting
process.
Foundry may
demand
modifications.

27. September 2005 Topology Optimization at 8

Volkswagen

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Topology Optimization of an engine bracket

Max : 130 MPa

Stress check of new design

Local shape improvement still
necessary

27. September 2005 Topology Optimization at 9

Volkswagen

Topology Optimization of an engine bracket

Final design

Stress reduction

Thicker rib means:

castable with better
performance

27. September 2005 Topology Optimization at 10

Volkswagen

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Topology Optimization of an engine bracket

AUDI A3 3,2 l V6 MPI 184 KW

27. September 2005 Topology Optimization at 11

Volkswagen

Topology Optimization of an engine bracket

Topology Optimization not correctly applied in model building and in programme use:

mass = 987 g mass = 1340 g

Result of external supplier Our result

27. September 2005 Topology Optimization at 12

Volkswagen

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Topology Optimization of an engine bracket

Topology Optimization not correctly applied :

Max stress: 183 MPa

Mass: 1025 g mass: 1120 g

Construction of external In comparison: Our
supplier was not carried out construction

27. September 2005 Topology Optimization at 13

Volkswagen

Bead design on heat shield

Position of the heat

shield in the engine

27. September 2005 Topology Optimization at 14

Volkswagen

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Bead design on heat shield

Design space First eigenmode

Design objective: Increase of natural frequencies

27. September 2005 Topology Optimization at 15

Volkswagen

Bead design on heat shield

Shape and position of beads:

3-D view of beads in IGES-format for the
Proposal of Topography Optimization
performance of the CAD
Input: 5 Eigenmodes &
prescription of a linear pattern

27. September 2005 Topology Optimization at 16

Volkswagen

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Bead design on heat shield

Final design:
Sheet metal thickness:
2 mm
Aluminium: 184 g

27. September 2005 Topology Optimization at 17

Volkswagen

Bead design on heat shield

Design Proposal of Final Improve-

space Optimi- Design ment in %
zation
1. mode 585 705 643 10

2. mode 590 725 676 15

3. mode 628 804 735 17

4. mode 727 952 900 24

5. mode 826 1190 1036 25

Results of optimizing the natural frequencies (in Hz)

27. September 2005 Topology Optimization at 18

Volkswagen

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Bead design on heat shield

Jetta 2,5 l R5 110 KW

27. September 2005 Topology Optimization at 19

Volkswagen

Design process
Topology Optimization
New development al course

Topology Optimization Given: Design space, loads, contraints

incorporated into the
Topology Optimizat ion
developmental process

Contruction by CAD

Stress Analysis w ith Topology Optimization

The length of the boxes
symbolizes the time Stress Analysis w ithout
demanded for the Topology Optimizat ion

performance of each Design adjustment: Thickness of items, radii, ...

task

Final component: Weight, stiffness and durability optimized

27. September 2005 Topology Optimization at 20

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Selection of optimized components

Bracket for air-conditioning compressor

Original Optimized
bracket design

271 g 225 g

20% weight reduction

27. September 2005 Topology Optimization at 21

Volkswagen

Selection of optimized components

Touareg 2,5 l R5 TDI 128 KW

27. September 2005 Topology Optimization at 22

Volkswagen

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Selection of optimized components

Combined bracket for alternator, air-conditioning compressor, and steering pump

2000 g 1550 g

Original shape Design space Topology result New design Stress check

27. September 2005 Topology Optimization at 23

Volkswagen

Selection of optimized components

Details of topology result

for the bracket :

Effect of manufacturing OFF

constraints: ON

27. September 2005 Topology Optimization at 24

Volkswagen

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Selection of optimized components

Multivan V6 3,2l 173 KW

27. September 2005 Topology Optimization at 25

Volkswagen

Selection of optimized components

Deflector ramp

US-NCAP* 35mph
Frontcrash
*New Car Assessment Program
Vehicle front axle
27. September 2005 Topology Optimization at 26
Volkswagen

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Selection of optimized components

Original shape: 992 g Design proposal

Saving: 20%
Material: steel
AQ 250 transmission
Position of hole is very sensitive to stress

US-NCAP 35mph Frontcrash

New design: 786 g

27. September 2005 Topology Optimization at 27

Volkswagen

Selection of optimized components

Combined bracket for alternator and air-conditioning compressor

Original shape Design space Topology New design Stress check

result

2018 g 1523 g 1698 g

27. September 2005 Topology Optimization at 28

Volkswagen

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Topology Optimization of an engine bracket

PASSAT V6 3,6 l FSI 206 KW

27. September 2005 Topology Optimization at 29

Volkswagen

Selection of optimized components

Combined bracket for alternator and air-conditioning compressor

Original shape Design space Topology New design Stress check

result
2058 g 1676 g

27. September 2005 Topology Optimization at 30

Volkswagen

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Selection of optimized components

Golf

Touran

2,0 l FSI 110 KW

27. September 2005 Topology Optimization at 31

Volkswagen

Topology/ Shape Optimization of an engine sector

Load case: Ignition pressure

Cut out

Critical areas:
stresses too high
Bearing pedestal

27. September 2005 Topology Optimization at 32

Volkswagen

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Topology/ Shape Optimization of an engine sector

New design Result of optimization

Area was defined by

19 design variables
Stress reduced by 10 %.
This version was produced.

27. September 2005 Topology Optimization at 33

Volkswagen

Topology/ Shape Optimization of an engine sector

New
Design space
design

Topology
proposal

Not possible to place

stress constraints into a
design area Mesh refined.
Stresses too
Construction was high
not carried out

27. September 2005 Topology Optimization at 34

Volkswagen

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Topology Optimization: Areas of application

Components Combined brackets

that have for alternator, air-conditioning compressor, steering pump, …
been
Engine brackets
optimized
Torque reaction mountings

fan-, cooler-, air intake pipe supports

exhaust manifold supports
case for chain drive
plastic suction pipes

deflector ramp for crash condition

control arms
roller finger follower for valve gear

Bead Optimization: sheet metal shields and -supports, oil sumps

27. September 2005 Topology Optimization at 35

Volkswagen

Consequences of weight reduction

Lower fuel consumption
Benefits Improvement vehicle driveability

Material costs Suitable for manufacture

X
X X
In order to avoid casting defects we had
to close 3 of 5 holes (X).

Combined bracket for New Beetle

27. September 2005 Topology Optimization at 36

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Consequences of weight reduction

Lower fuel
consumption
100 kg* reduction
saves 0.35 l / 100 km and
(= gain of 0.85 mpg)
8.4 g CO2/km
or
to decrease 1g CO2/km
Other parameters infuencing fuel reduce weight -12 kg
consumption:
* Reference car with 1300 kg

Rolling resistance

Aerodynamic resistance

Electricity consumption

27. September 2005 Topology Optimization at 37

Volkswagen

Summary

Topology Optimization incorporated into the design process means:

Conception of virtual vehicle
- Careful and accurate collection of load information is necessary
- Design decisions made by computational optimization
- Ensure durability by reliable calculation
- Do not dispense with experimental tests, but confine them to validate the final state

Reduce new product development time to market

Lower costs
Produce fuel-efficient and environmentally justifiable vehicles

27. September 2005 Topology Optimization at 38

Volkswagen

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Thank you very much.

All the work involved was carried out in excellent

co-operation with the computational department,
all design departments and the test center.
All staff members have contributed equally to the
final success.

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