An Optimization Analysis on an Automotive Component with Fatigue Constraint Using HyperWorks Software for Environmental Sustainability
A finite element analysis (FEA) computer software HyperWorks is utilized in re-designing an automotive component to reduce its mass. Reduction of components mass contributes towards environmental sustainability by saving world-s valuable metal resources and by reducing carbon emission through improved overall vehicle fuel efficiency. A shape optimization analysis was performed on a rear spindle component. Pre-processing and solving procedures were performed using HyperMesh and RADIOSS respectively. Shape variables were defined using HyperMorph. Then optimization solver OptiStruct was utilized with fatigue life set as a design constraint. Since Stress-Number of Cycle (S-N) theory deals with uni-axial stress, the Signed von Misses stress on the component was used for looking up damage on S-N curve, and Gerber criterion for mean stress corrections. The optimization analysis resulted in mass reduction of 24% of the original mass. The study proved that the adopted approach has high potential use for environmental sustainability.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1327626Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3790
 M. Zurofi, Manufacturing Process Effects on Fatigue Design and Optimization of Automotive Components–An Analytical and Experimental Study, The University of Toledo, Ph.D. thesis, 2004.
 K. Krishnapillai And R. Jones, "Fatigue based 3D structural design optimization implementing genetic algorithms and utilizing the generalized Frost-Dugdale crack growth,” Proc. of the 9th WSEAS Int Conf. on Mathematical and Computational Methods in Science and Engineering, Trinidad and Tobago, 2007.
 P. Chaperon, R. Jones, M. Heller, S. Pitt & F.Rose, "A methodology for structural optimization with damage tolerance constraints,” Engineering Failure Analysis, vol.7, 2000, pp. 281-300.
 Y. Kojima, "Mechanical CAE in automotive design,” R & D review of Toyota CRLD, Vol 35, No. 4, 2000.
 U. Schramm, H. Thomas, and M. Zhou, "Manufacturing considerations and structural optimization for automotive components,” SAE Technical Paper, No. 2002-01- 1242, Society of Automotive Engineers, 2002.
 Altair Hyperworks10, Altair Engineering Inc., India, 2009.
 "Fatigue and fracture”, ASM Handbook, Vol 19, ASM International, 1996.
 E. Zahavi, V. Torbilo, Fatigue Design - Life Expectancy of Machine Parts, CRC Press, 1996.
 M.P. Bendsoe, O. Sigmund, Topology Optimization - Theory, Methods and Application, Berlin,Heidelberg: Springer-Verlag, 2003.
 M. Bendsoe, N. Kikuchi, "Generating optimal topologies in structural design using a homogenization method”, Computer Methods in Applied Mechanics and Engineering, Vol. 71, 1988, pp. 197-224.
 R.A. Richards, Zeroth-Order Shape Optimization Utilizing A Learning Classifier System, PhD Dissertation, Mechanical Engineering Department, Stanford University, 1995.