SAE TECHNICAL PAPER SERIES

2008-36-0371

Topologic Optimization Applied to an Auxiliary Organs Bracket of an Automotive Engine

Robinson Ferrari Barbosa FPT Fiat Powertrain Technologies Tas Santos Sampaio, MSc Vision Graphic Design Erlon Castro Rodrigues FPT Fiat Powertrain Technologies Ricardo Luiz Utsch de Freitas Pinto, PhD Universidade Federal de Minas Gerais (UFMG) Demec - CEA

FILIADA

XVII Congresso e Exposio Internacionais da Tecnologia da Mobilidade So Paulo, Brasil 07 a 09 de outubro de 2008

AV. PAULISTA, 2073 - HORSA II - CJ. 1003 - CEP 01311-940 - SO PAULO SP

2008-36-0371

Topologic Optimization Applied to an Auxiliary Organs Bracket of an Automotive Engine

Robinson Ferrari Barbosa
FPT Fiat Powertrain Technologies

Tas Santos Sampaio, MSc

Vision Graphic Design

Erlon Castro Rodrigues

FPT Fiat Powertrain Technologies

Ricardo Luiz Utsch de Freitas Pinto, PhD

Universidade Federal de Minas Gerais (UFMG) Demec - CEA
Copyright 2008 Society of Automotive Engineers, Inc

ABSTRACT The need of mass reduction of automotive engines, aiming at greater performance of the vehicle and cost reductions, demands the research for optimized forms of all its components. The mass minimization of all parts of the engine is not limited only to the optimization of the mechanical project of the part in itself. A part with less weight or volume, saves used material, makes it possible to increase the part production, it facilitates transportation, and, therefore, allows reducing the final cost of the part throughout all its productive chain. In this work the method of Topological Optimization (TO) was applied to project a new geometry, using cast iron, for the alternator and air conditioner compressor bracket of a automotive engine, originally in aluminum. Two geometries had been proposed: one where it is considered manufacture process and another one where it is not considered. The last one was used as step for the optimization of final geometry. Through the topological optimization it was possible to design a significantly cheaper automotive bracket in cast iron with similar mass comparing to original aluminum alloy bracket in use, which reaches the same project requirements. INTRODUCTION The optimization applied to the design of mechanical components is used in order to create a shape that reaches all functional requirements in the best possible way. It consists in using computational

methods to get the optimum dimensions, shapes or topology of a component. The weight reduction of mechanical components and the performance improvements allowed by the use of optimization techniques are very relevant. It can define the competitiveness of metal-mechanic industry among competitors, being costs reduction of undeniable importance. The impact of a component mass reduction is felt throughout all productive chain, as it makes logistics easier, and therefore, it allows further component costs reduction and also the final product. Designing an engine cylinder block with all auxiliary organs attachments already integrated is very difficult due to the large number auxiliary components. It becomes impracticable when you consider the auxiliary organs and layout variations normally required by different vehicle applications. For these reasons, brackets are used. And they must resist the vehicle normal and abusive utilization efforts, resist the transmission belt dynamic forces, and also belt tensioning stresses generated by the automatic belt tensioner. The present work aims to apply structural optimization to design an auxiliary organs bracket of an internal combustion, four cylinders engine. Specifically optimize the alternator and air conditioning compressor bracket, using the topological optimization method and a specific CAE software for structure discretization, and components static and modal analysis.

Usually these brackets are manufactured in aluminum alloy because they produce lighter brackets then the ones in cast iron. However, its cost may be till three times greater than the cast iron. On the other hand, the simple material substitution is impracticable once manufacture processes are different. Cast iron presents density about three times greater than aluminum alloy. The simple substitution would increase significantly total engine mass, what could be harmful for the vehicle performance. OPTIMIZATION TOPOLGICA (OT) The topological optimization (TO) is a computational method that allows predicting an optimum structure topology, according to a specified objective function. The TO distributes the material at the interior of a fixed shape domain in order to maximize or minimize a specified cost function (for example, maximum rigidity and minimum material volume). The material in each point of the domain can vary from air (without material presence), until solid (total material presence), being able to assume intermediate densities between air and solid, according to a defined material model. An optimization algorithm is used to find, in an iterative way, the optimum material distribution, speeding the process. If it were not used, a large number of unnecessary analyses would be made to finally find the optimum material shape in the domain. For the acceleration of calculation process, the optimization method uses the objective function gradients information in relationship to the amount of material in each element. The material distribution is represented associating a material density value to each element (sub domains). These sub domains are obtained through the initial domain discretization (mesh). Then TO essentially combines optimization methods with the finite elements method (FEM). METHODOLOGY Figure 01 below shows engine auxiliary belt drive with the current aluminum alloy bracket:

NATURAL FREQUENCY EVALUATION The three first frequency modes were calculated for the bracket. An internal procedure specifies that the first mode frequency must be above the minimum value of 275 Hz. CRITICAL LOADING CASES DETERMINATION The internal procedure specifies some events for simulation. Table 01 shows the applied load cases. Table 01 - Applied load cases. Acceleration (G) Load Case X -1GY -1GZ -1GX -1GZ -4GZ -27GX-1GZ -1G -27G Y -1G Z -1G -1G -4G -1G

To all these load cases it was added the forces transmitted by the auxiliary belt drive work. The forces values for each auxiliary belt drive component used were determined by the auxiliary belt supplier, as shown in Figure 02 and Table 02.

Figure 02 Auxiliary belt drive components. Table 02 Forces applied in auxiliary belt drive

Source: belt supplier

Bracket Alternator Compressor Tensioner Belt Idler Cover Engine

Figure 01: Auxiliary belt drive The optimization process followed these steps:

COMPLIANCE EVALUATION - Compliance and displacements were evaluated in structure load application points in the current component for baseline. The weighted compliance value was used in first optimization analysis (without considering manufacturability). After the generation of the first geometry, a new analysis was run generating new compliance values. These values were used as constraint for final optimization, considering manufacturability.

EXTENDED FIX DOMAIN DETERMINATION - A solid representing the greatest volume the bracket could occupy (space design) was created. This is the optimization domain. Figure 03 illustrates this space design.

Constraint four: complience 80 N.mm The compliance value used in the first optimization was obtained by current component analysis. After the generation of the first optimized geometry, a new analysis was run. A new value for weighted compliance was generated and then, it was used as constraint for the final optimization considering draw directions. It was not inputted stress constraint to this topological optimization once the algorithm developed for this requires too much memory, and, in most cases, the problem becomes unstable and does not converge. This way, stress levels were verified after the optimization analysis. OPTIMIZATION RESULTS INTERPRETATION - After the topological optimization, results were interpreted in way to generate a guide geometry using the OSSMOTH tool of OptiStruct software. As result of optimization analysis, it is presented elements with intermediate densities, between solid and total air. From the result evaluation, it was determined which elements must remain so that all constraints are reached. The density limit was defined, below of which elements must be discarded. This value is inputted to software, through OSSMOTH tool. This tool generates surfaces over external contour of the optimization resultant geometry, creating a guide geometry, which will be used as basis for the creation of a new CAD geometry. NEW GEOMETRY GENERATION - Over the guide geometry it was created the new CAD geometry. This new geometry must try to replicate as best as possible the guide geometry, so the new bracket will behave as close as possible to the optimization result. Some small modifications are accepted to satisfy all manufacturing requirements. Finally, the new geometry mesh was generated to verify the stress levels (constraint considered inactive), and the natural frequency modes. ANALYSIS AND RESULTS CURRENT BRACKET - Figure 04 shows first three frequency modes resultant from modal analysis of the current bracket.

Figure 03 Space Design. MATERIAL CHOOSING - It was defined that the component would be made in gray cast iron (in substitution to the aluminum alloy), and should have the first frequency mode above the calculated objective (275Hz). In relation to stresses, it should present maximum stress inferior to 2/3 of the materials yield stress, value determined by an internal procedure for the materials fatigue limit. The bracket will have to support the alternator, the air conditioning compressor, the belt idler and tensioner, and all the involved dynamic forces. The bracket is fixed to the engine block by six attachment points. It was chosen cast iron because it has an unitary cost three times cheaper than aluminum alloy, which makes possible a significant cost reduction. MANUFACTURING CONSTRAINTS - This is a determinative stage in solving the problem. The considering of casting process generate an addition of mass in the final result in relationship to the optimization result without considering manufacture requirements. For the casting process it is necessary that each branch of the component to have a minimum thickness (minimum member size) greater than 6.0 mm. Beyond that, it is fundamental to consider the draw directions. This way, despite the optimization analysis without consideration of manufacturability generates an extremely slim structure, it is not feasible, once there are no available manufacture process to produce it. OBJECTIVE FUNCTION AND CONSTRAINTS DEFINITION - For the present problem it was considered the following formulation: Objective function: mass, to be minimized Constraint one: 1st frequency mode 280Hz Constraint two: 2nd frequency mode 285Hz Constraint three: 3rd frequency mode 290Hz

340 Hz

435 Hz

498 Hz

Figure 04 First three mode of current bracket.

Table 03 shows the result of current bracket static analysis for the four events previously defined. Table 03 Proposal 01: Stress Results. Stress target Von Mises Event (MPa) (MPa) -1GY -1GZ -1GX -1GZ -4GZ -27GX -1GZ 130 130 130 130 1.4 10. 12.3 14.9

Figure 07 below presents the CAD geometry generated from the optimization result.

SF 92 12 10 8 Figure 07 Proposal 01: CAD geometry from optimization result.

NEW BRACKET OPTIMIZATION MODELING - The optimization domain was discretized using tetrahedral elements. The auxiliary organs were represented by mass elements and fixed to the extended domain through rigid elements (RBE2). The auxiliary belt drive forces were applied to the rigid elements master nodes. The accelerations considered for each load case were applied to entire model. The design space is shown in Figure 05, together nondesign space. It corresponds to the attachments that must remain (layout constraints).

Table 04 shows proposal 01 values of stress for the studied events. Table 05 shows values of compliance, mass and natural frequency. Table 04 Proposal 01: Stress values. Von Stress target Event Mises (MPa) (MPa) -1GY -1GZ -1GX -1GZ -4GZ -27GX -1GZ 130 130 130 130 7.53 43.3 42.5 53.4

SF 17 3.0 3.0 2.4

Design Space Non-Design Space

Figure 05 Design Space OPTIMUM GEOMETRY WITHOUT CONSIDERING MANUFACTURABILITY After running the topological optimization analysis, results were interpreted in order to generate a guide geometry, using tool OSSmoth of OptiStruct software. This tool generates surfaces over external elements contour of the optimization result by means of smoothing it. It creates a geometry that will be used as basis for the generation of a new CAD geometry. Figure 06 shows this optimization result.

Table 05 Characteristics of resultant geometry. Mass 1.886,0 g Compliance 79,8 N.mm 1 Mode 243 Hz

As the part will be manufactured in cast iron, the result of the optimization without draw direction criteria still does reach all manufacture requirements. However, new process techniques or possible modifications in current process manufacture can, eventually, make possible it. A good aspect of this optimized geometry is that it presents satisfactory flexibility, not necessarily optimum. It presents a lower value of compliance than the current bracket. Also, even the result of optimization without draw direction resulted lower value of mass than current bracket, proposal 01 is not approved in modal analysis once its first mode is below the procedure frequency target. OPTIMUM GEOMETRY CONSIDERING MANUFACTURABILITY - As already discussed, the resultant geometry shown above does not possess guarantee of being manufacturable, at least not for the

Figure 06 Optimization Distribution in domain

Results:

Material

available processes. Therefore, it is necessary to also run an optimization analysis considering draw directions. Moreover, the compliance of the first optimization result without considering draw directions will be adopted as constraint for the optimization analysis considering draw directions. Figures 08 and 09 show the process iteration for objective function and the first constraint, respectively.

The same way it was done to proposal 01, it was generated a new geometry after the smoothing of the optimization result considering draw directions, as shown in Figure 11 below:

Figure 11 Proposal 02: Optimized geometry.

4,00 3,50 3,00

Objective

2,50

Mass (kg)
2,00 1,50 1,00 0,50 0,00 1 4 7 10 13 16 19 22 25 28 31 34 37 40

In order to confirm that proposed geometry attends to requirements, a linear static analysis was carried out to verify the stress levels (constraint considered inactive in optimization) and also a modal analysis to verify natural frequencies of the structure. The Modal Analysis led to the results shown in Figure 12. First three natural frequency modes are shown.

Iteration

Figure 08: Process iteration for objective function.

First Mode

1500,00

F irs t C o n s tra in

1200,00 900,00

295 Hz
Frequency (Hz)

535 Hz

667 Hz

600,00 300,00 0,00 1 4 7 10 13 16 19 22 25 28 31 34 37 40

Figure 12 Modal analysis results for optimized geometry Table 06 shows Von Mises stress results for each studied event. Event -1GY -1GZ -1GX -1GZ -4GZ -27GX -1GZ Stress Target (MPa) 130 130 130 130 Von Mises (Mpa) 12.8 12.3 13.0 27.0

Iteration

Figure 09: Process iteration for first constraint. The optimum density distribution (bracket with minimum weight) for the optimization where if it considers the draw directions, is shown in Figure 10.

From the result of modal analysis, first frequency mode (295 Hz > 275 Hz) confirms that the natural frequency constraint was respected in the optimization result considering the draw directions. Stress values are much lower than material yield strength. The most severe load case presented the maximum stress value of 27 MPa, corresponding to a security factor of 4.8. This finally confirms the optimum behavior of this problem once stress

Figure 10 Optimization result: Material distribution.

constraint had been considered inactive at the beginning of the optimization analysis and structure does not fail when submitted to the efforts applied. RESULTS DISCUSSION Table 07 presents the values of mass, natural frequency, compliance and maximum tension for proposal 01, proposal 02 and current in production bracket. Table 07: Comparison of results
Bracket Figure Material Mass 1st mode 2nd mode 3rd mode Compliance Stress Aluminum 2432 g 340 Hz 435 Hz 498 Hz 52,9 N.mm 14,9 MPa Cast Iron 1886 g 243 Hz 322 Hz 370 Hz 79,98 N.mm 53,4 MPa Cast Iron 2404 g 295 Hz 535 Hz 667 Hz 15,4 N.mm 27,0 Mpa Current Proposal 01 Proposal 02

distribution, according to dominium elements density, it was obtained a 900g mass for the component. But it was estimated that would be necessary the increase of about 500g to get manufacturability. This way, the final result would be a final mass reduction of about 1kg, getting a unitary cost reduction of about 41%, smaller than the reduction obtained by the optimization considering cast iron. CONCLUSION The application of optimization techniques to products design, in special to mechanical systems structural components, is the basis for the conception of a competitive product design. By using topological optimization, it was possible to design an automotive bracket of cast iron with similar mass in comparison with original aluminum alloy bracket in use, reaching the same design requirements, but significantly cheaper. By cost research, the new bracket can provide to the manufacturer a cost economy greater than R$5.000.000, 00 per year. It could be noticed that, not only the structural integrity requirements are important in an optimization analysis, but it is also essential to input manufacture requirements to get a successful design. REFERENCES [1] SCHRAMM, U., ZHOU, M., TANG, P., HARTE, C. G., Topology layout of Structural Designs and Buckling. Irvine, Altair Engineering, Inc. 2005. 6p. [2] LEAL, V., CARDOSO, V. M., ZAMBELLI, L., CARNEIRO, G., BITENCOURT, R.. Shape And Topologic Optimization Of Engine Mounts. So Paulo: Society of Automotive Engineers, Inc, 2006. 8p [3] BENDSOE, M. P., Optimization of Structural Topology, Shape and Materia, Springer-Verlag, 1ed, New York, 1995. [4] BENDSOE, M. P., Kikuchi, N., Generating Optimal Topologies in Structural Design Using a Homogenization Method, Computer Methods in Applied Mechanics and Engineering, 71, pp. 197-224, 1988. [5] NISHIWAKI, S., MIN, S., YOO, J., KIKUCHI, N., Optimal Structural Design Considering Flexibility, Computer Methods in Applied Mechanics and Engineering, p190, 2001.

Proposal 01 presents a thinner geometry than current in production geometry (1,886 g), offering a 22% reduction in weight. However, it fails in natural frequency constraint (first mode=243Hz < 275 Hz). It is not a feasible project then. On the other hand, proposal 02, even so it offers a smaller weight reduction in comparison with proposal 01 (only 1.2% reduction in relationship with the current one), it reaches all design requirements, beyond presenting a smaller value of compliance (15.4 < 52.9) Thus, it can be concluded that proposal 02 represents a viable geometry with significantly inferior manufacture cost when compared with current in production bracket. Taking into account that cast iron is about 2.5 times cheaper than aluminum alloy (prices survey carried through) and the weights of both proposed and current in production geometries are very similar, the proposed bracket will be 2.62 times cheaper than the current bracket. FINAL COMMENTS Based in a market research done at may/2008 Belo Horizonte/MG (Brazil), a kilo of gray cast iron costs about 40% of a kilo of aluminum alloy. Changing the original part for the new optimized one in cast iron leads to a annual economy of about R$ 5,145,000.00, leaving the relevance of the present study evident. It was also run the optimization analysis considering the aluminum alloy as material for the optimized bracket. Based on optimum material