OTC VW Presentation.pdf

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1、Kostenstelle04.10.2005,Kostenstelle,1Welcome!Dr.RainerMeyer-PruessnerOTC05September27th–28th,2005OptimizationTechnologyTroy,MI,USAConferenceSignificantWeightReductionbyUsingTopologyOptimizationinVolkswagenDesignDevelopmentwithemphasisonenginedesign27.September2005TopologyOptimizationat2Volkswa

2、gen1Kostenstelle04.10.2005,Kostenstelle,2AgendaoHowwestarted…oExample:designdevelopmentofanenginebracketoExample:designdevelopmentofaheatshieldoCourseofthedesignprocessoSelectionofoptimizedcomponentsoShape/TopologyOptimizationofanenginesectoroAreasofapplicationoConsequencesofweightreductionoSu

3、mmary27.September2005TopologyOptimizationat3VolkswagenHowwestarted…EnginebracketforT4952g733gNewdesignadaptedtoloadcondition,i.e.materialisremovedwherenotcontributingtoloadcarryingcapacityApril199727.September2005TopologyOptimizationat4Volkswagen2Kostenstelle04.10.2005,Kostenstelle,3TopologyOp

4、timizationofanenginebracketZYXPrincipleconfiguration:Enginebearing–enginebracketDesignobjective:enginebracketaslightaspossible-madefromaluminium27.September2005TopologyOptimizationat5VolkswagenTopologyOptimizationofanenginebracketLoadimpactDesignspaceForcesapplied:-onlongitudinalaxis-onvertica

5、laxisBolt-onpointsforengineblock-forassembly27.September2005TopologyOptimizationat6Volkswagen3Kostenstelle04.10.2005,Kostenstelle,4TopologyOptimizationofanenginebracketDesignproposal:Constructionaccordingtodesignproposal.BestmaterialdistributionunderimpactofallSuitabilityforcastingmustbetakenf

6、orces&includingmanufacturingconstraints,intoaccount.i.e.demoldingdirection27.September2005TopologyOptimizationat7VolkswagenTopologyOptimizationofanenginebracketComputersimulationofcastingprocess.Foundrymaydemandmodifications.27.September2005TopologyOptimizationat8Volkswagen4Kostenstelle04.10.2

7、005,Kostenstelle,5TopologyOptimizationofanenginebracketMax:130MPaStresscheckofnewdesignLocalshapeimprovementstillnecessary27.September2005TopologyOptimizationat9VolkswagenTopologyOptimizationofanenginebracketFinaldesignStressreductionTh