OptimizationofAluminiumMaterial.PDF

Optimization of Aluminium Material Use For an Automotive Crankcase Author: Michal B ?ezina September 2008 RD.08/299801.1 ? Ricardo plc 2008 Content
Purposes and goals of the thesis
Loading analysis of the crankcase
Creating of the model
Topology optimization
Results and evaluation
Alternative approach RD.08/299801.1 ? Ricardo plc 2008 2 Introduction
Needs of emissions reduction (legislation) and fuel consumption (customers) looking for weight saving
HOWEVER, crankcase of combustion engine contains up to 50% of material which is not useful for structural rigidity Necessary for separation and sealing of engine’s fluids.
Is it possible to remove the material?
How? RD.08/299801.1 ? Ricardo plc 2008 3 Main Goals Possible solution: Creating of skeletal block (used in stationary engines). Goal of the thesis: Develop a process for creating optimized design of skeletal block by using topology optimization. RD.08/299801.1 ? Ricardo plc 2008 4 Analysis of Acting Forces Acting Forces in a crankcase:  Forces from gases pressure  Inertial forces and centrifugal forces Scheme of acting forces:  Moment from gearbox  Forces from bolts pretension Engine’s parameters: Volume 1600 cm 3 Cylinders 4 Bore 76,5 mm Stroke 86,9 mm Conrod length 131 mm Cylinder spacing 81 mm Main bearings 5 RD.08/299801.1 ? Ricardo plc 2008 5 Model (CATIA - HyperMesh)
Creating of model (CATIA)
Transferring the model to the software Altair-HyperMesh?
Creating of