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Altair Technology ConferenceDesign Optimization of Axles using Inspire and OptistructMay 5-7, 2015
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AAM Products
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Customers
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
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Carrier Optimization
Working spaceOptimized 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
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Optimization Concept and Real Design
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)
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Gear Deflection Comparison
20% Mass ReductionWith 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
Leakage ValidationShear Displacement Comparison @ 2G
beaming Load
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New DesignBaseline Design
20% Mass Reduction
Prototype Passed Hardware Testing
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Topology Optimization in AAM
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• Design improvement for NVH performance
Brown color is topology optimized rib addition for reinforcement
Topology Optimization in AAM
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Original Design Optimized Design
Torque carrying capacity increased three times
Prototype Passed Testing
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Topology Optimization in AAM
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Axle Design for Performance and Light Weighting
Current Cast Iron Design12.52 Kg
Revised Aluminum Design5.3 Kg
Optimization Process
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Design Space for Manufacturing Process and Functional Loads
Topology Optimized Result
Interpretation and RealizationFunctional Validation with FEA
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Axle Design Out of Optimization Step
A manufacturable designNot an abstract concept
Internal gear and lubrication flow is fixed
External Packaging space is fixed
Stress Riser Avoidance – rib and boss connection
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Design Space
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
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Manufacturing Constraints
Set maximum rib thickness as the maximum element size
Transfer loads to bearings, bushings and connection interfaces
Durability requirements, Gear Loads
NVH Stiffness requirements
Casting requirements
Component study with System Boundary Conditions
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Load Consideration
Critical Issues for Meaningful Optimization
How to combine different load cases, NVH requirements, Casting Requirements into one Optimization Target Setting?
Target Setting
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Use Existing Product to setup compliance target
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Approach for Re-Designing an Existing Product
For Inspire – adjust force levels to achieve same compliance for different load casesFor Optistruct – Appropriately use displacement control
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
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For Brand New Design
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Summary
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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