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Dr. D.

Sprengel 6/2007 Topology Optimization of EMS Bracket 1 ( 21 )


Topology Optimization of Engine Mount Brackets
Dr. Dirk Sprengel
Ford Werke GmbH
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 2 ( 21 )
EMS Bracket Funktion
EMS: Engine Mount System
Link between engine and body
EMS bracket assembled with:
Cylinder Head
Engine mount
Alternator
(Cover)
Durability crash, extreme driving conditions
NVH, driving comfort no transfer, amplification of engine vibrations,
no eigenmodes in driving range
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 3 ( 21 )
Problem Definition, Task
Conventional bracket design:
EMS involved into several engine eigenmodes
Local EMS frequency below target of 500 Hz
(example: 420, 470 Hz)
Run Topology Optimization to
Improve modal behaviour of bracket ( f
i
> 500 Hz )
( Ensure durability )
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 4 ( 21 )
Define Optimization Volumes and Design Rules
Draw directions
Obstacles
~ 200.000 elements
regular voxel mesh
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 5 ( 21 )
Optimization Submodel, Boundarys, Loads
Static: loads
F
bolt
50 kN
+ F
h
10 kN
+ F
h
- 10 kN
+ F
v
10 kN
+ F
v
- 10 kN
+ F
l
10 kN
Dynamic: max. Eigenfreq.:
Alternator horz. + EMS
EMS local (>500Hz)
Alternator vert.
5x
Cylinder Head
Engine Block
Alternator
EMS Ring
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 6 ( 21 )
Optimization Run Design Recommendation
Iteration 19
Density >= 0.3
Color: casting constraints
Run OptiStruct
Min. Compliance @ Static Loads 5x
Max. Eigenfrequencies No. 1,2,3
Volume: 30%of design space
(~ old bracket volume)
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 7 ( 21 )
Robustness Check of Optimization Run
The optimization seems to be robust, the final design was useful.
Base features have been recommended for new CAD geometry.
Not used (model size) Other OptiStruct features (maxmb)
Not checked: Change of draw directions
Not checked Change of boundary conditions or loads
20% results in weaker design with
same design features
Influence of Volumefrac target :
20% instead of 30%
Changed weight factor: 10x
small design changes
Check balance between:
Min. compliance ( static )
Max. Eigenfrequencies ( modal)
Main features with
small design changes
Single Optimization Frequency
(w/o static loads)
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 8 ( 21 )
Opti CAD Geometry FE check
Modal analysis of complete P/Train:
Reduced participation of EMS
1. Local EMS Mode from 470 Hz to 681 Hz
No check of stress distribution
new part
CAD / FE
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 9 ( 21 )
Next Task: Changed Engine Installation Angle, Position
Prototype (449 Hz, local stress concentrations) improve it!
Changed bolt position results
in a deep hole ( cast draw )
Stress concentration
Changed bolt position results
in a sharp corner near a thread
Stress concentration
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 10 ( 21 )
Bracket II Optimization Task
Dynamic: 500 Hz
Static : Min. compliance
+ Stress reduction
Topology
Optimization
OptiStruct + Engineering Judgement !!
The definition of design space + draw rules should lead
to an optimization result with feasible stress distribution.
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 11 ( 21 )
Bracket II Optimization Model: Single / Split Draw
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 12 ( 21 )
Optimization Model: Final Cut
Design space Cut out
to avoid stress concentration or to reduce mass concentration
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 13 ( 21 )
Bracket II Optimization Run CAD
CAD Added features
( lifting eye, cover flange,)
OptiStruct
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 14 ( 21 )
Dynamic Performance
Modal behaviour
CAD FEM remeshed, complete P/Train
EMS 1. Mode: 538 Hz
(Prototype: 449Hz, Target: 500Hz)
general: reduced modal EMS participation
Stress distribution
No direct optimization task,
driven by model features
see next pictures
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 15 ( 21 )
Stress Analysis: Bolt foces 50 kN + EMS vertical 10 kN
Prototype Design Final Design
Critical
high tension
at corner
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 16 ( 21 )
Stress Analysis: Bolt foces 50 kN + EMS vertical 10 kN
Stress Analysis Bolt foces 50 kN + vertical EMS load 10 kN
Prototype Design Final Design
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 17 ( 21 )
Successful EMS Evolution
High improvement of part functionality
Bracket I
Modal 681 Hz
Robustness study (optimization model, loads, parameters)
Bracket II :
Modal 538 Hz
Stress distribution durable
Based on bracket I model, experience
Well prepared for stress reduction
Lecture What structure do we really need?
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 18 ( 21 )
Start Product Development with Optimized Design
Base design features
by
Optimization
First in Chain!
Short time reaction
with
Optimization tool
+
Concept Job 1 Product Development
Cost of changes
Design changes
T
a
r
g
e
t
s
e
t
t
i
n
g
Time
Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 19 ( 21 )
Education
Process Management
Opti CAD CAE First in Chain!
CAE: Optimization
Take the lecture! What structure do we really need?
Improve process
Persuade people
All
Update Engineering Judgement
No Design by Rules
Design by Need
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Final Message
Optimize !
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Thank You!