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1.ThyssenKruppGroup
Organization
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected]
)
Page#2/21
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2.ForgingGroupGlobalPresence
10ManufacturingSites
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected]
)
Page#3/21
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3.ProductPortfolio
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#4/21
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4.TechnicalPresentation
Crankshaft 7.7L study: 42CrMo4 steel by SAE1548 and
38MnSiVS5;
The approval criteria: Crankshaft under engine operation;
Stresses results under virtual engine operation: Post-processed
using
analytical and flexible approach;
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#5/21
The analytical analyses were carried out for the speed range
from 800 until
2300 rpm. Moreover, an detailed flexible analysis was performed
@ 2300 rpm.
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7.StructuralFatigueSafetyFactor@CurrentWebs
w04 w12
A-42CrMo4 1.06 1.57
B-38MnSiVS5 0.99 1.47
C-SAE1548 0.91 1.35
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#8/21
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8.GeometryandboundaryconditionsusedinShapeOptimization
ThyssenKruppForgingGroup
VirtualPowertrain Conferece Brazil
August
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#9/21
Mesh detailsNodes :693499
Elements:479114Elemtype:tet10Linearoptimization
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Objectivefunction:MinimizeVonMises
equivalentstress15optimizationsteps
Softwareused:TOSCA7.1.1
VonMisesStress(Mpa)
8.1.1.Shapeoptimization#1 frontwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#10/21
Optimized region frontregion
Reference node
(#122011)forstresscontrol
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Equivalent stress(MPa)
8.1.2.Shapeoptimization#1 frontwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#11/21
Displacement (mm)
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Commentsabouttheresults:
Forthestep#15,theoptimizationresultsshowastressreductionof15%(VonMises
EquivalentStress).
Althoughthisresultofstressreductionisnotsoconsiderable,itshowsthetendencyofoptimizationdesign,throughthenodaldisplacement.
Nodal displacement
8.1.3.Shapeoptimization#1 frontwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#12/21
OriginalmodelOptimization
step#15Tendencydesignof
shapeoptimization
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Basedonthetendencyshownbytheresultsoftheshapeoptimization:
Originalmodel
Proposedmodel#1model newradius
8.1.4.Shapeoptimization#1 Designproposalsforfrontwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#13/21
Mass originalmodel throw#1=12.56Kg
Mass model#1 throw#1=12.59Kg
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VonMises
Stress(MPa)
Proposedmodel#1model newradius
8.2.Shapeoptimization#2 backwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#14/21
Reference node
(#861395)forstresscontrol
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Equivalent stress(MPa)
8.2.1.Shapeoptimization#2 backwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#15/21
Displacement (mm)
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Commentsabouttheresults:
Forthestep#15,theoptimizationresultsshowastressreductionof16%(VonMises
EquivalentStress)forthe
webbackregion.Althoughthisresultofstressreductionisnotsoconsiderable,itshowsthetendencyofoptimizationdesign,throughthenodaldisplacement.
8.2.2.Shapeoptimization#2 backwebregion
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#16/21
OriginalmodelOptimization
step#15Tendencydesignofshapeoptimization
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CurrentDesign Finaloptimizeddesignafterlastoptimization
8.3.ShapeOptimization DesignProposal
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust
2012CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#17/21
Mass
Current Design
(reference)
Final Optimized
design
Difference from
Reference (%)
Throw #1(Kg) 12.56 12.63 0.56
Entire Crankshaft (Kg) 69.78 70.05 0.39
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8.4.ShapeOptResults DesignProposalsforbackwebregion
Summarytable safetyfactor
optimizationresultsofthebackwebregion
Original
model
Model#1-
newradius-
reference
model
Model#2-
newradius-
backweb
region
difference
from
reference
(%)
difference
from
original
model (%)
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust 2012
CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#18/21
safetyfactor 2.31 2.35 3.12 +32.77 +35.0
mass(kg)-
1throw12.56 12.59 12.62 0.24 0.48
Chosenoption
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9.StructuralFatigueSafetyFactor@OptimizedWebs
w4 w12
A-42CrMo4 1.33 1.96
B-38MnSiVS5 1.24 1.84
C-SAE1548 1.14 1.69
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust 2012
CT-TKMCL,AlexdeSouzaRodrigues([email protected])
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10.Comments
BendingBenchTest
Failuremode Failuremode
ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust 2012
CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#20/21
TorsionBenchTest
Failuremode
Crankshaftunder
Engineoperation
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ThyssenKruppForgingGroup
VirtualPowertrain Conferece BrazilAugust 2012
CT-TKMCL,AlexdeSouzaRodrigues([email protected])
Page#21/21
Thanks!
