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Direct Optimization of an Automotive Sheet Metal Part Using ANSYS
134-142Views:443Optimization of automotive parts nowadays is mainly used to design lightweight and cost-effective vehicle parts in order to improve the cost and efficiency. In this research, a sheet metal part was taken into consideration and optimized using direct optimization module in ANSYS to evaluate the process. An initial Finite Element Analysis (FEA) was done on the sheet metal part by adding forces and constraints in order to initiate direct optimization. The purpose of the optimization is to minimize the mass of the sheet metal part and maintaining a certain Factor of Safety (FOS) by automatically modifying the sheet thickness and the dimension of the side holes. As a result, the best candidate point with 23% mass reduction was found which complied with FOS value was selected for optimal geometry.
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Topology Optimization of Automotive sheet metal part using Altair Inspire
143-150Views:836In an optimization problem, different candidate solutions are compared with each other, and then the best or optimal solution is obtained which means that solution quality is fundamental. Topology optimization is used at the concept stage of design. It deals with the optimal distribution of material within the structure. Altair Inspire software is the industry's most powerful and easy-to-use Generative Design/Topology Optimization and rapid simulation solution for design engineers. In this paper Topology optimization is applied using Altair inspire to optimize the Sheet metal Angle bracket. Different results are conducted the better and final results are fulfilling the goal of the paper which is minimizing the mass of the sheet metal part by 65.9% part and Maximizing the stiffness with Better Results of Von- Miss Stress Analysis, Displacement, and comparison with different load cases. This can lead to reduced costs, development time, material consumption, and product less weight.
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Optimization of the Sheet Metal Base of a Toggle Clamp Using Finite Element Method
266-273Views:221Optimization relates to the ultimate yield strength and the maximum stress incident on the current model under critical working conditions and finds through iterative processing a way to compensate for the strength requirement without going beyond the desired mass limits. In this paper, the horizontal sheet metal base of a horizontal toggle clamp is optimised for mass reduction using the finite element analysis in the computer aided design software. The sheet metal base material is the ANSI32 Steel. In the design software, it is designed with the thickness of 7 mm and it is intended to support a workload of up to 750 N. The constraints were a fixed point added at all the holes and at the bottom surface of the sheet metal base. A number of iterations were made for the 750N loading force across the base plate to run the simulation. For optimization, the aim was to minimize the mass of the base plate. The design parameters were Von Mises, factor of safety and displacement. The variables were the slots’ width and material thickness along the mid-surface of the sheet metal. The mass was reduced by more than thirty per cent overall.
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Applicability of Optimization Methods in the Design of Automotive Rubber Products
358-363Views:154Size, shape or topology optimization are widely used to fulfil the requirements in the design process of rubber products. In many cases, the shape of the product is very complex and comes into contact with other components during operation. It is commonly subjected to large deformation for which the rubber shows strongly nonlinear behaviour. For this complex problem analytical solution is not available, thus finite element method could be used in which the analysis running is a time consuming process. The object of my research is to compare the efficiency and computational cost of different optimization algorithms. This article focuses on the applicability of various optimization methods in the field of automotive rubber goods. Direct search optimization and surrogate model optimization methods will be introduced.
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Application of Topological Methods in the Development of Vehicle Components
67-75Views:107Many areas of the industry are characterized by continuous changes, which define new directions of development in product design. The development of computers and software, the spread of modern production tools and the development of material technology make it possible to expand traditional production technologies with modern processes. Integrated CAD systems have occupied their place in the product design and development process for decades, reforming classical design methods. Popular optimization procedures in integrated CAD systems, such as shape optimization, topological optimization and the new generative design process, provide effective solutions for design engineers in more and more industrial application areas. Experience shows that modern design methods can be used in many areas of industry. The appearance of metal powder printing and additive technology make it possible to test the designed prototypes or even to produce the final products. The following article aims to support the above with the help of a case study.
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Solid-Lattice Stem Optimization Design for Hip Implants
39-46Views:429The goal of this study is analyzed and design a methodology to reduce stem mass, through topology and lattice optimization of a Ti-6Al-4V hip implant, meeting yield stress requirements. Four optimization cases were studied: Topology optimization (1), Lattice design 100% (2), Lattice design 50% (3), Lattice design 25% (4). Five load cases from a study were applied for each optimization cases: Combined (LC1), standing-up (LC2), standing (LC3), going up stairs (LC4), jogging (LC5). The optimized cases design reduced stem mass approximately by 30% (1), 5% (2) ,8% (3) and 2% (4), compared with the total stem hip Ti-6Al-4V implant.
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Topology optimization and rim design
92-101Views:294A goal of this article is to show the development of the car wheel rims along with the progress of the manufacturing technologies over the past few years. To achieve this goal, topology optimization and generative design usage have been reviewed in this work. The research has focused on the main factors, which affect the life of car wheel rim, and it has shed the light on the effect of the topology optimization and the generative design on the manufacturing of the car wheel rims. Since the main factors above-mentioned are the: forces, material preferences and topology optimization, the study has covered the results of the studies made on each part along with the technology progress. Moreover, the article has explained the methodology main steps of the topology optimization and the generative design and their principles.
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Manufacturing Process Optimization and Tool Condition Monitoring in Mechanical Engineering
72-89Views:194The optimization of manufacturing and production processes with various computer software is essential these days. Solutions on the market allow us to optimize and improve our manufacturing and production processes; one of the most popular software is called Tecnomatrix, which is described in this paper. Tool condition monitoring is a vital part of the manufacturing process in the industry. It requires continuous measurement of the wear of the cutting tool edges to improve the surface quality of the work piece and maintain productivity. Multiple methods are available for the determination of the actual condition of the cutting tool. Vibration diagnostics and acoustic methods are included in this paper. These methods are simple, it requires only high sensitive sensors, microphones, and data acquisition unit to gather the vibration signal and make signal improvement. Extended Taylor equation is applied for tool edge wear ratio. Labview and Matlab software are applied for the measurement and the digital signal processing. Machine learning method with artificial neural network is for the detection and prediction of the edge wear to estimate the remaining useful lifetime (RUL) of the tool.
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Component Development Using Topological Methods
54-62Views:95The article aims to briefly summarize the design aids which can be used nowadays, such as topology optimization and generative design, which are common in integrated CAD systems. A case study is used to present the results and comparisons provided by the previously mentioned methods.
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Numerical Modelling and Simulation of Sheet Metal Forming Process
1-6.Views:163Simulation and modelling of sheet metal forming process are well common today in different industries (automotive, aerospace) and several research centers regarding its huge impact for both on production and reliability of the lifecycle of the equipment, and the quality of the product. However, to obtain the best configuration possible with the inputs parameters to achieve high level of production and increasing the durability of the tools needs some extra methods for the optimization for this problem using mostly finite element method cooperated with iterative algorithms based on Artificial Neural Network (ANN) [1]. Whereas this research is focused on modelling of stamping process of stainless steel AISI 304 to investigate to formability of the material, and studying the influence of the friction factor on the quality of the product as well the energy required for each set configuration.
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Generative Design of a Mechanical Pedal
48-58Views:849Nowadays, there are various tools that support the initial stages of design available to use for engineers, the traditional Computer-Aided Design (CAD) has been implemented in the engineering components design and replaced manual drafting. However, with the advances and the rapid technology development, new trends emerged to cope with this evolution, namely, Generative Design, Topology Optimization, and Generative Engineering Design. The method is based on numerical algorithms that generate a variety of design and modelling options based on the criteria and constraints set by the designer to allow further design exploration. Proposed in this paper is an implementation of the generative design of a mechanical pedal with further finite element analysis.
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Simulation of BLDC Motor Drive Systems for Electric Vehicles Using Matlab Simulink
48-52Views:256The defining scientific developments of our time would not have been possible without the use of simulations. The aim of the research is to create a simulation of a BLDC motor. When creating a simulation, great emphasis must be placed on defining the purpose of the simulation. This basically determines the structure and complexity of the model. The model discussed here was created so that an optimization task could be defined more precisely by inserting it as a sub-model into a vehicle dynamics model. Scalability was another aspect, that is, to be able to increase the accuracy of the model with measured data in the future, as well as to be able to validate it. During the research, a BLDC motor efficiency map generation program was created, as well as an environment for testing the generated data. The created system gives researchers the opportunity to use a shape-correct efficiency model when simulating a BLDC motor even without measured data. This makes it possible to discover real relationships between model parameters when performing optimization.
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Introduction to Design and Analysis of Torsional Vibration Dampers in Vehicle Industry
310-324Views:343The crankshaft of today’s internal combustion engines with high performance output are exposed to harmful torsional oscillations originated from the unbalanced gas and inertial forces. To avoid the fatigue damage of engine components, caused by the undesired vibrations, torsional vibration dampers can be applied. Viscodampers are one type of the torsional vibration dampers, which operational fluid is silicone oil. For cost-effective R&D activities and production, finite element and finite volume numerical discretization methods based calculation techniques must be involved into the engineering work supported by the modern computer technology. The aim of this paper is to provide an insight into the multidisciplinary design and development process of visco-dampers in vehicle industry applications. Four different examples as structural, fatigue, CFD analyses and structural optimization have been introduced in the present work. It turned out from the static structural and fatigue analyses, that the investigated damper has safety factor over the limit for both static structural and fatigue analyses, so it is suitable for the given load conditions. In the structural optimization process 34.36% mass reduction has been achieved. According to the coupled fluid dynamic and heat transfer simulations a rather stagnating air zone evolved between the engine and the damper during the operation, which can cause efficiency reduction of cooling fins mounted onto the housing. In light of the numerical results, the suitable damper position has been determined for the highest heat transfer.
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Maintenance from the Work Safety Point of View
190-196Views:137Deterioration of the technical condition of plant equipment is a common phenomenon nowadays. According to the experience of authorities, all this contributes to the occurrence of malfunctions and accidents. Plants that operate with an inadequate conservation strategy are now nearing the end of their design life, thus posing an increased accident risk. Aging processes are often accelerated by the operator's underestimation of the effects of equipment stress and the extent of deterioration mechanisms, and the consequent inadequate design and operation of condition monitoring and maintenance procedures. The aim of our work is to examine trends in the light of modern maintenance optimization methods and, in connection with this, to make proposals for the optimization of maintenance scheduling for employers.
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Efficiency Analysis of Production Management System
401-415Views:218Due to the continuously evolving technology, even more escalating market competition has emerged between the companies. This competition is not only about the logistics related processes, it also appears to be significant for the production since the manufacturing companies form the center of global sale streams and without them the items found in logistical processes cannot be created. The role of production’s optimization and efficiency in the supply chain continuously grows since this is the part where a company’s most cost is produced. Our research objective was the examination of a company that applies various manufacturing, assembly technologies, and the used tools and softwares for this purpose were the SAP Business One ERP system and it’s add-on, called PPS One, the latter originated in Switzerland. We used these softwares to provide solutions to companies, especially to those that are dealing with manufacturing and production, for the optimization of their workflows, operations, supervising and controlling of their material. We also monitored from production technology’s elements the capacity planning, production orders, schedules, production tracking and cost accounting. We have made proposals during the analysis that might improve the company's strategy, competitiveness and increase it’s efficiency in business, and at the same time they can facilitate the company's pricing and inventory management activities.
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Generative Design of Articulated Rod of Radial Engine
36-47Views:482The constant need for improvement drives humans to look for the best possible option in every field. Computer Aided Design (CAD) is no exception, to follow the best method of designing a product and finalizing it, researchers came up with an idea to generate multiple designs using fixed input values and finalizing the most appropriate one. The objective is achieved using an iterative design process based on algorithms by a specific software. Generative design introduces a new experience based on the Integration of machine dynamics in the manufacturing of objects and about experience. In this work generative design method was investigated on an articulated rod, one of the most important components of the rotary engine, to effectively improve the overall working performance of the engine and enhance its performance by decreasing its mass. Since fuel consumption by the machine can be greatly reduced by lowering the mass, so the goal is to minimize the weight of the rod while mechanical characteristics have to be within the acceptable values. Also, finite element analysis (FEA) was investigated on the part as to ensure the reliability of the rod before and after optimization.
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Automated static structural FEA environment in MATLAB using Solid Edge and Femap
17-22Views:111Nowadays, CAD and FE software are getting integrated to each other. However, these new integrated pieces of software cannot be customized enough to analyze different optimization methods or model behavior. In this paper, a MATLAB environment is developed that connects to C# and VB programs, which use Solid Edge and Femap API functions, in order to automate the geometry modification and the FE model building and solving functions. A simple static structural size optimization problem is solved with the fmincon solver of MATLAB.
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Topology Optimization of Acetabular Cup by Finite Element Simulation
22-34Views:438Hip replacements typically consist of a four-part piece. Our research will focus primarily on the acetabular component. Several different types of materials can be used when creating a hip replacement implant ranging from plastic to titanium. Different materials are used to accommodate for allergic reactions or circumventing potential health risks. Aside from the material, the size of the components plays a factor in terms of durability; a larger diameter head might avoid dislodgement though it could increase wear and tear on the stems through constant friction. A patient’s force applied to the hip replacement is usually measured through a number of physical assessments. Finite element analysis (FEA), a computer-based method of data observation, allows for us to accurately simulate hip forces and their impact on the hip replacements. Through this, it becomes easier to predict and calculate the performance of specific designs. Generative systems can also be used to support performance analysis and optimization through assessing a multitude of cases, many of which apply in real-world scenarios. By applying both systems, we designed and modeled an acetabular cup that when measured decreased the mass from 129 grams initially down to 52 grams, a 60% decrease in total mass. Furthermore, the design we created lessened the trauma on the piece through distributing force across the entirety of the piece rather than specific segments only. This shows an increased durability and life expectancy when compared to usual acetabular cups.
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Use of ANSYS Software for the Acetabular Cup Structure Analysis out of the Hip Implant
1-6.Views:358Modelling the hip implant has been one of the most important researches over the past few decades. In addition, using the ANSYS software for this purpose is well-known procedure to understand the real reaction of the hip implant parts during the daily life of the installed part. This study is to focus on the practical part of the use of ANSYS software to analyse the performance of the hip implant through the feature of structure analysis available in the ANSYS. The research applies the static loads behaviour only with the help of the static structural analysis to view the advantages and the disadvantages of every design, which helps us estimate the implant’s behaviour. The study investigates the optimization of the acetabular cup using the lattice optimization along with the infill option available in the ANSYS software in order to optimize the stress and the fixture of the cup inside the pelvis.
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Exhaust System Muffler Volume Optimization of Light Commercial passenger Car Using Transfer Matrix Method
132-138Views:192Nowadays, the automotive industry is focused on weight and size reduction. Main advantage of this weight and size reduction are improving the fuel economy. The specific fuel consumption of a vehicle can be improved through e.g. downsizing area of heat loss, if we focus on vehicle with weight reduction. Weight reduction can be done by replacing material or by changing the size (dimensions) of components. In the present work we have focused on Audi A6 muffler, troubleshooting and optimizing the muffler by changing pipe length of inlet and outlet, also by replacing the original mesh plate to porous pipe. Based on optimization, prototype has been built with the help of 3D design tool CATIA V5 and the calculations of transmission loss (TL) have been performed by MATLAB. Plane wave-based models such as the transfer matrix method (TMM) can offer fast initial prototype solutions for muffler designers. The principles of TMM for predicting the transmission loss of a muffler was used. Result of this present study of an existing muffler has been analysed and then compared with vehicle level test observation data. Noise level have been optimized for new muffler design. Other literatures were played significant rule for validate our results.
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Analysis of Activity Times in the Process of a Wooden Box Manufacturing
475-484Views:140The main target of companies is to earn money and achieve profit. In order to fulfil these needs, companies have to reduce their costs. Cost reduction is often associated with bad quality products, but it could be done in a different way. Sometimes it is enough to examine only their own processes and then benefit from the process optimization, process improvement or process scheduling. In this article a case study is presented, in which the differences in a production scheduling are evaluated with the application of Monte-Carlo simulation and descriptive statistics. At the end of the paper the most efficient material sequence is selected at the manufacturing company by using weighted sum model
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Optimization of Automotive Industry’s Manufacturing Process with Lean Tools
81-89Views:394Lean plays i mportant role in industrial environment. Automotive industries use lean tools in order to reduce cost and i mprove productivity. To achieve the company's objectives and so lve the detected problems I also used lean tools. By using lean tools we want to decrease total process cost (TPC). In order to achieve this target, the three-shift production has to reduce in two-shift production, which result decrease in the human resource costs and production costs. In order to reduce shifts we have to increase overall equipment efficiency (OEE) and eliminate minimum 50% of wastes by implementing 5s methodology, using Poka-yoke and scheduled maintenance.
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Process Innovation Tools and Strategies in Production Management
148-162Views:343The method of process innovation helps to recognize the opportunities in production processes that represent clear competitive advantage. Using it, up to 30% change is available in increasing productivity and in the reducing of costs, stocks, and lead times. There is no need for complicated methods in the process development. The power of logical, simple tools relies on the fact that everyone can learn, understand, apply them and give quick feedback about their operation. Significant changes have been made in today's possibilities of designing and operating production systems. The emergence of cyber physical systems, the opportunities offered by big data, and the "Internet of Things" (Internet of Things) have shown strong research potential for more efficient logistics and manufacturing systems. The potential of network co-operation, information gathered from tracing materials in production and communication between machines provide a wide-range of optimization opportunities for manufacturing processes. The toolkit presented in the research cannot only be used in direct production; almost all parts of the value creation process can be broken down into routine actions, so the causes of the problems can be analyzed and the development of the process’ parts can be easier implemented.
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Mechanical Design and Finite element Analysis for Acetabular cup
23-35Views:135Hip replacements typically consist of a four-part piece. Our research will focus primarily on the acetabular component. Several different types of materials can be used when creating a hip replacement implant ranging from plastic to titanium. Different materials are used to accommodate for allergic reactions or circumventing potential health risks. Aside from the material, the size of the components plays a factor in terms of durability; a larger diameter head might avoid dislodgement though it could increase wear and tear on the stems through constant friction. A patient’s force applied to the hip replacement is usually measured through a number of physical assessments. Finite element analysis (FEA), a computer-based method of data observation, allows for us to accurately simulate hip forces and their impact on the hip replacements. Through this, it becomes easier to predict and calculate the performance of specific designs. Generative systems can also be used to support performance analysis and optimization through assessing a multitude of cases, many of which apply in real-world scenarios. By applying both systems, we designed and modeled an acetabular cup that when measured decreased the mass from 129 grams initially down to 52 grams, a 60% decrease in total mass. Furthermore, the design we created lessened the trauma on the piece through distributing force across the entirety of the piece rather than specific segments only. This shows an increased durability and life expectancy when compared to usual acetabular cups.
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Business Strategy in the Model of Linear Activity Analysis of Production
1-14Views:189It was analyzed how the methodology of linear activity analysis of production model supports the implementation of different business strategies at a company level. Aspects of analysis are focusing on openness for markets, lean management and environmental protection strategies. The study reveals that the linear activity analysis of production – mainly due to its efficient process optimization problem solving ability – is capable supporting lean management decisions and implementing additional objectives in business strategies. Such objectives can be sustaining specific production patterns for further development or following strategies for limiting market competition. It will be shown how to quantify the costs of strategic objectives in linear activity analyzing model.
