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Design Optimization of Axles using Inspire and OptiStruct

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  1. 1. Altair Technology Conference Design Optimization of Axles using Inspire and Optistruct May 5-7, 2015
  2. 2. 2 AAM Products
  3. 3. 3 Customers
  4. 4. Topology Design Optimizations in AAM Design Optimization with INSPIRE and Optistruct Case History of Using Topology Optimization Manufacturing Consideration Target setting process with Multiply load case Outline 4
  5. 5. Carrier Optimization Working space Optimized ribbing design -Use cover bolt flange to strengthen vertical beaming - use ribs connecting trunion and pinion bearing area to improve gear support * Use Vertical Beaming and Gear Forward and Reverse loading with manufacturing consideration. * Perform Topology Optimization Finite Element Analysis
  6. 6. top bottom top bottom Optimization Concept and Real Design
  7. 7. New DesignBaseline Design Baseline Carrier: 48.0 Kg New Carrier: 38.3 Kg Optimized ribbing design Use cover bolt flange to strengthen vertical beaming use ribs connecting trunion and pinion bearing area to improve gear support (patent pending)
  8. 8. 8 Gear Deflection Comparison 20% Mass Reduction With Gear Deflection Improvement Gear Separation Baseline Design Optimized Design e - Vertical 0.343 mm 0.335 mm p - Pinion axis 0.331 mm 0.324 mm g - Gear Axis 0.098 mm 0.084 mm
  9. 9. Leakage Validation Shear Displacement Comparison @ 2G beaming Load 9 New DesignBaseline Design 20% Mass Reduction
  10. 10. Prototype Passed Hardware Testing 10
  11. 11. Topology Optimization in AAM 11 Design improvement for NVH performance Brown color is topology optimized rib addition for reinforcement
  12. 12. Topology Optimization in AAM 12 Original Design Optimized Design Torque carrying capacity increased three times
  13. 13. Prototype Passed Testing 13
  14. 14. Topology Optimization in AAM 14 Axle Design for Performance and Light Weighting Current Cast Iron Design 12.52 Kg Revised Aluminum Design 5.3 Kg
  15. 15. Optimization Process 15 15 Design Space for Manufacturing Process and Functional Loads Topology Optimized Result Interpretation and RealizationFunctional Validation with FEA
  16. 16. 16 Axle Design Out of Optimization Step A manufacturable design Not an abstract concept
  17. 17. Internal gear and lubrication flow is fixed External Packaging space is fixed Stress Riser Avoidance rib and boss connection 17 Design Space
  18. 18. Define parting line and draw direction joint decisions with manufacturing engineer, product engineers, CAE and CAD Different material requires different mesh size control in solving Sand Casting and Die Casting using different size control 18 Manufacturing Constraints Set maximum rib thickness as the maximum element size
  19. 19. Transfer loads to bearings, bushings and connection interfaces Durability requirements, Gear Loads NVH Stiffness requirements Casting requirements Component study with System Boundary Conditions 19 Load Consideration
  20. 20. Critical Issues for Meaningful Optimization How to combine different load cases, NVH requirements, Casting Requirements into one Optimization Target Setting? Target Setting 20
  21. 21. Use Existing Product to setup compliance target 21 Approach for Re-Designing an Existing Product For Inspire adjust force levels to achieve same compliance for different load cases For Optistruct Appropriately use displacement control
  22. 22. Establish Optimization Target Range for Different Load Cases Displacements with full design space and without design space Estimate to establish Target and Design Density relationship With sensitivity calculation Meaningful optimization can be achieved in 2-3 runs Methodology 22 For Brand New Design 10target 10 Target , SpaceDesignofdensityiswhere ;,%100;,%0 ;, D FDfFDf FDf d d
  23. 23. Summary 23 AAM has developed Topology optimization process using balanced Multi-Physics target setting procedure with Manufacturing considerations The results of Optimization process are manufacturable designs, not just a concept designs Design parts show significant mass reduction is possible; performance improvement has been validated through hardware testing
  24. 24. Jerry Chung, Ph.D. Sr. Manager, Analytical Engineering 313-758-2000 24

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