ThyssenKrupp Forging Group ThyssenKrupp 1/14 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
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
1/14
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
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
2/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
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
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
3/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
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
Stop Condition: none
Design Variables: webs critical nodes
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
4/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
Material Removal
Topology Optimization
Shape Optimization
1.2.1. Crankshaft Oil Hole Chamfer Optimization
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
5/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
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%)
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
6/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
1.2.2 Crankshaft Oil Hole Chamfer Topology Optimization
- 18%
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
7/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
Current Oil Hole Design Optimized Oil Hole Design
CA
DCAE
1.2.3. Crankshaft Oil Hole Shape Optimization
S1 Stress: 618 MPa S1 Stress: 469 MPa (-
24%)
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
8/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
1.2.3. Crankshaft Oil Hole Chamfer Shape Optimization
- 22%
Current Oil Hole Design Optimized Oil Hole Design
+
28%
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
9/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
DAMAGE: 14.9
DAMAGE: 2.2
DAMAGE: 106.1
DAMAGE: 5.9material added
1.3. Crankshaft Webs Shape Optimization
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
10/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
Current
Optimized
1.3. Crankshaft Webs Shape Optimization
+ 2.74% Mass
- 20%
+
25%
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
11/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
+ 0.22% Mass
1.3. Crankshaft Webs Shape Optimization
- 20%
+
25%
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
12/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
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
Stop Condition: none
Design Variables: Small End
Nodes
160 kN
30 kN
Engine Loads
236 kN
67 kN
Fatigue Test
Loads
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
13/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
2.2. Pinless Connecting Rod – Topology Optimization
TKThyssenKrupp Forging Group
Th
ys
se
nK
rup
p
14/14
Crankshafts and Connecting Rods Structural Optimization May’ 2010
DAMAGE: 20 DAMAGE: 2
material added
2.3. Pinless Connecting Rod – Shape Optimization
Related Documents
