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Altair Technology Conference Design Optimization of Axles using Inspire and Optistruct May 5-7, 2015

Design Optimization of Axles using Inspire and OptiStruct

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Page 1: Design Optimization of Axles using Inspire and OptiStruct

Altair Technology ConferenceDesign Optimization of Axles using Inspire and OptistructMay 5-7, 2015

Page 2: Design Optimization of Axles using Inspire and OptiStruct

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AAM Products

Page 3: Design Optimization of Axles using Inspire and OptiStruct

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Customers

Page 4: Design Optimization of Axles using Inspire and OptiStruct

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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Page 5: Design Optimization of Axles using Inspire and OptiStruct

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

Page 6: Design Optimization of Axles using Inspire and OptiStruct

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Optimization Concept and Real Design

Page 7: Design Optimization of Axles using Inspire and OptiStruct

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)

Page 8: Design Optimization of Axles using Inspire and OptiStruct

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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

Page 9: Design Optimization of Axles using Inspire and OptiStruct

Leakage ValidationShear Displacement Comparison @ 2G

beaming Load

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New DesignBaseline Design

20% Mass Reduction

Page 10: Design Optimization of Axles using Inspire and OptiStruct

Prototype Passed Hardware Testing

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Page 11: Design Optimization of Axles using Inspire and OptiStruct

Topology Optimization in AAM

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• Design improvement for NVH performance

Brown color is topology optimized rib addition for reinforcement

Page 12: Design Optimization of Axles using Inspire and OptiStruct

Topology Optimization in AAM

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Original Design Optimized Design

Torque carrying capacity increased three times

Page 13: Design Optimization of Axles using Inspire and OptiStruct

Prototype Passed Testing

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Page 14: Design Optimization of Axles using Inspire and OptiStruct

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

Page 15: Design Optimization of Axles using Inspire and OptiStruct

Optimization Process

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Design Space for Manufacturing Process and Functional Loads

Topology Optimized Result

Interpretation and RealizationFunctional Validation with FEA

Page 16: Design Optimization of Axles using Inspire and OptiStruct

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Axle Design Out of Optimization Step

A manufacturable designNot an abstract concept

Page 17: Design Optimization of Axles using Inspire and OptiStruct

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

Page 18: Design Optimization of Axles using Inspire and OptiStruct

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

Page 19: Design Optimization of Axles using Inspire and OptiStruct

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

Page 20: Design Optimization of Axles using Inspire and OptiStruct

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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Page 21: Design Optimization of Axles using Inspire and OptiStruct

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

Page 22: Design Optimization of Axles using Inspire and OptiStruct

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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Page 23: Design Optimization of Axles using Inspire and OptiStruct

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

Page 24: Design Optimization of Axles using Inspire and OptiStruct

Jerry Chung, Ph.D.Sr. Manager, Analytical Engineering

313-758-2000

[email protected]

24www.AAM.com