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 Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 20 ( 21 ) Final Message Optimize ! Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 21 ( 21 ) Thank You!