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Design of Reliable Lightweight Cast Components: An Optimization Driven Design Appraoch
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
2018 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesisAlternative title
Tillförlitlig lättviktsdesign av gjutna komponenter : En optimeringdriven konstruktionstrategi (Swedish)
Abstract [en]

The present-day automotive industry is striving to design lightweight components by optimizing the design for minimization of weight. The topology optimization is used widely for the design of lightweight components. The casting process is time and cost effective for mass production and widely adopted within the automotive industry. Generally, castability is not considered in the weight optimization process. These weight optimized components are optimized once again in the later stage for cost-effectiveness in the casting process. The modified design usually weighs more than the weight optimized design. The design can be optimized for weight and castability simultaneously in the early stage of design and this thesis report presents an optimization process for the same.

The optimization process presents effective usage of the topology optimization to design lightweight components without compromising castability. It is a three-step process where thetopology optimization is integrated with solidification simulation along with DFX -castability evaluation. The reliability of the conceptual design is predicted based on the mapping of solidification and stress hotspots. The process is implemented to design three components of Scaniatruck and weight is reduced by 15% to 25%.

Abstract [sv]

Dagens bilindustri strävar efter att utforma lätta komponenter genom att optimera designen för att minimera vikt. Topologioptimering används i stor utsträckning för design av lätta komponenter. Gjutningsprocessen är tids-och kostnadseffektiv för massproduktion och allmänt vedertagen inom bilindustrin. Generellt ingår inte gjutbarhet i viktoptimeringsprocessen. Dessa viktoptimerade komponenter optimeras igen i ett senare skede för kostnadseffektivitet vid massproduktion. De flesta gånger är viktoptimerade koncept modifierade för att erhålla kostnadseffektivitet vid gjutning genom att lägga till extra vikt. I den här rapporten presenteras enoptimeringsdriven designprocess för att få pålitlig lättviktsgjutbar design.

Optimeringsprocessen presenterar effektiv användning av topologioptimering för att utformalätta komponenter utan att kompromissa med gjutbarheten. Det är en trestegsprocess där topologioptimering integreras med förstärkningssimulering tillsammans med utvärdering avDFX-sårbarhet. Tillförlitligheten hos den konceptuella designen förutses baserat på kartläggningav stelningen och spänninggskoncentrationer. Processen är implementerad för att optimera utformningen av tre komponenter i Scania-lastbilar och vikten minskas med 15% till 25%.

Place, publisher, year, edition, pages
2018. , p. 102
Series
TRITA-ITM-EX ; 2018:370
Keywords [en]
Topology Optimization, Solidification Simulation, Cast Components, Early Stage Castability Evaluation
Keywords [sv]
Topologioptimering, Simulering av stelning, Gjutna Komponenter, utvärdering av gjutbarhet
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:kth:diva-239573OAI: oai:DiVA.org:kth-239573DiVA, id: diva2:1266008
External cooperation
Scania CV AB
Subject / course
Machine Design
Educational program
Master of Science - Engineering Design
Presentation
2018-06-11, 15:13 (English)
Supervisors
Examiners
Available from: 2019-02-20 Created: 2018-11-26 Last updated: 2019-02-20Bibliographically approved

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