ii seminário a otimizaÇÃo de produtos automotivos · thyssenkrupp forging group 1/14 tkrupp...

TKThyssenKrupp Forging Group

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Crankshafts and Connecting Rods Structural Optimization May’ 2010

II Seminário A OTIMIZAÇÃO DE PRODUTOS AUTOMOTIVOS

Crankshaft and Connecting Rods Structural Optimization

17.05.2010

Msc. Luis Galli

Development Engineering Manager

ThyssenKrupp Metalúrgica Campo Limpo

E-mail: [email protected]

Phone: +55-11-4039-9432

mailto:[email protected]


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Agenda

1. Crankshaft Optimization

1.1 Boundary Conditions

1.2 Oil Hole Chamfer Optimization

1.3 Webs Optimization

2. Pinless Connecting Rod

2.1 Boundary Conditions

2.2. Topology Optimization

2.3. Shape Optimization


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1.1. Boundary Conditions for Crankshaft Oil Hole and Webs Optimization

Torsion Fatigue Test

T

Topology Optimization (oil hole):

Objective Function: min Volume

Constraints: compliance

Stop Condition: equivalent stress

Design Variables: oil Hole Chamfer nodes

Shape Optimization (oil hole):

Objective Function: minimize S1

stress

Constraints: none

Stop Condition: none

Design Variables: oil hole chamfer

nodes

Shape Optimization (webs):

Objective Function: minimize

Damage

Constraints: none


Design Variables: webs critical nodes


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Material Removal

Topology Optimization

Shape Optimization

1.2.1. Crankshaft Oil Hole Chamfer Optimization


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Current Oil Hole Design Optimized Oil Hole Design

CA

DCAE

1.2.2 Crankshaft Oil Hole Topology Optimization

S1 Stress: 280 MPa S1 Stress: 226 MPa (-

19%)


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1.2.2 Crankshaft Oil Hole Chamfer Topology Optimization

- 18%


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CA

DCAE

1.2.3. Crankshaft Oil Hole Shape Optimization

S1 Stress: 618 MPa S1 Stress: 469 MPa (-

24%)


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1.2.3. Crankshaft Oil Hole Chamfer Shape Optimization

- 22%


+

28%


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DAMAGE: 14.9

DAMAGE: 2.2

DAMAGE: 106.1

DAMAGE: 5.9material added

1.3. Crankshaft Webs Shape Optimization


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Current

Optimized


+ 2.74% Mass

- 20%

+

25%


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+ 0.22% Mass


- 20%

+

25%


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2.1. Pinless Connecting Rod – Boundary Conditions

Topology Optimization

Objective Function: min Compliance

Constraints:

Volume target 60%

Stop Condition:

Fatigue damage

Contact pressure

Design Variables:

Whole connecting rod

elements density

Shape Optimization Parameters:

Objective Function: min Damage

Constraints: none


Design Variables: Small End

Nodes

160 kN

30 kN

Engine Loads

236 kN

67 kN

Fatigue Test

Loads


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2.2. Pinless Connecting Rod – Topology Optimization


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DAMAGE: 20 DAMAGE: 2

material added

2.3. Pinless Connecting Rod – Shape Optimization

ii seminário a otimizaÇÃo de produtos automotivos · thyssenkrupp forging group 1/14 tkrupp...

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