Optimization Of Automotive Components

Abstract

This dissertation work aims to role of structural optimization in design and product development. Today market demands for more efficient product in low cost. To fulfill the market demands it is necessary to improve design of product constantly and to decrease its manufacturing time. Structural optimization plays very important role in R&D of product. There are different types of structural optimization like Topology, Shape & Size. Topology is widely accepted by industry. Shape and Size optimization is still developing. There are different mathematical techniques to solve the optimization problem. Homogenization method is one of those methods which are in use in industry. To solve optimization problem is very long and tough process. And to solve industrial problem mathematically is almost impossible. To save time of solving process software are developed. They are programmed to solve problem by mathematical iterations. And complicated problem can be solved by computer in some hours. Optistruct is very famous solver to solve optimization problem developed by Altair Engineering. In this thesis whole optimization of ‘Front Pedestal of Cement Mixer Truck” is performed. Starting from design space to final CAD model generation. Here Topology and Shape optimization is carried out. After the analysis it is concluded that new design is safe then current component used. And new design is also showing 36% weight reduction, this turns in to very large cost benefit. Along with ‘Front Pedestal’ Topology Optimization of “Cross Member of Chassis” is also carried out. This is a live project of company. From the given loads and boundary conditions by customer new optimized shape is developed for the component. This will helpful in reducing assembly time and manufacturing time. Preprocessing of both the components and meshing is done in’ Hypermesh’. Optimization is carried out using ‘Optistruct’. Analysis of both components for different Load Cases is done in ‘Abaqus’. During the redesign of component and its CAD model generation ‘Unigraphics’ is used.