Topology Optimization of Engine Mount Brackets

Dr. Dirk Sprengel

Ford Werke GmbH

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 1 ( 21 )

 EMS Bracket Funktion

EMS: Engine Mount System

Link between engine and body

EMS bracket assembled with:
• Cylinder Head
• Engine mount
• Alternator
• (Cover)

 Durability crash, extreme driving conditions

 NVH, driving comfort no transfer, amplification of engine vibrations,
no eigenmodes in driving range

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 2 ( 21 )

 Problem Definition, Task

„Conventional“ bracket design:

• EMS involved into several engine eigenmodes
• Local EMS frequency below target of 500 Hz
(example: 420, 470 Hz)

Run Topology Optimization to

• Improve modal behaviour of bracket ( fi > 500 Hz )
• ( Ensure durability )

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 3 ( 21 )

 Define Optimization Volumes and Design Rules

• Draw directions
• Obstacles

• ~ 200.000 elements
regular voxel mesh

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 4 ( 21 )

 Optimization Submodel, Boundarys, Loads

Cylinder Head Alternator

Static: loads
• Fbolt 50 kN
+ Fh 10 kN
+ Fh - 10 kN
+ Fv 10 kN 5x
+ Fv - 10 kN
+ Fl 10 kN

Dynamic: max. Eigenfreq.:

• Alternator horz. + EMS
• EMS local (>500Hz)
Engine Block EMS Ring • Alternator vert.

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 5 ( 21 )

 Optimization Run  Design Recommendation

 Run OptiStruct
• Min. Compliance @ Static Loads 5x
• Max. Eigenfrequencies No. 1,2,3

• Volume: 30% of design space

(~ old bracket volume)

Iteration 19
Density >= 0.3
Color: casting constraints

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 6 ( 21 )

 Robustness Check of Optimization Run

Single Optimization  Frequency Main features with

(w/o static loads)  small design changes
Check balance between: Changed weight factor: 10x
Min. compliance ( static )  small design changes
Max. Eigenfrequencies ( modal)
Influence of Volumefrac target : 20% results in weaker design with
20% instead of 30%  same design features
Change of boundary conditions or loads Not checked

Change of draw directions Not checked:

Other OptiStruct features (maxmb) Not used (model size)

The optimization seems to be robust, the final design was useful.

Base features have been recommended for new CAD geometry.

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 7 ( 21 )

 Opti  CAD Geometry  FE check

new part
CAD / FE

• Modal analysis of complete P/Train:

• Reduced participation of EMS
• „1. Local“ EMS Mode from 470 Hz to 681 Hz
• No check of stress distribution

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 8 ( 21 )

 Next Task: Changed Engine Installation Angle, Position

Prototype (449 Hz, local stress concentrations)  improve it!

Changed bolt position results Changed bolt position results

in a sharp corner near a thread in a deep hole ( cast draw )
 Stress concentration  Stress concentration

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 9 ( 21 )

 Bracket II Optimization Task

Dynamic: 500 Hz Topology

Static : Min. compliance Optimization

+ Stress reduction

OptiStruct + Engineering Judgement !!

The definition of design space + draw rules should lead

to an optimization result with feasible stress distribution.

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 10 ( 21 )

 Bracket II Optimization Model: Single / Split Draw

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 11 ( 21 )

 Optimization Model: ‚Final Cut‘

Design space ‚Cut out‘

• to avoid stress concentration or to reduce mass concentration

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 12 ( 21 )

 Bracket II Optimization Run  CAD

OptiStruct CAD Added features

( lifting eye, cover flange,…)

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 13 ( 21 )

 Dynamic Performance

• Modal behaviour
– CAD  FEM remeshed, complete P/Train
– EMS 1. Mode: 538 Hz
(Prototype: 449Hz, Target: 500Hz)
– general: reduced modal EMS participation

• Stress distribution
– No direct optimization task,
driven by model features

–  see next pictures

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 14 ( 21 )

 Stress Analysis: Bolt foces 50 kN + EMS vertical 10 kN

Prototype Design Final Design

Critical
high tension
at corner

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 15 ( 21 )

 Stress Analysis: Bolt foces 50 kN + EMS vertical 10 kN

Prototype Design Final Design

Stress Analysis Bolt foces 50 kN + vertical EMS load 10 kN

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 16 ( 21 )

 ‚Successful EMS Evolution‘

High improvement of part functionality

• Bracket I
• Modal  681 Hz
 Robustness study (optimization model, loads, parameters)

• Bracket II :
• Modal  538 Hz
• Stress distribution  durable
 Based on bracket I model, experience
 Well prepared for stress reduction

Lecture ‚What structure do we really need?‘

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 17 ( 21 )

 Start Product Development with Optimized Design

Cost of changes

Target setting

Design changes

Time
Concept Product Development Job 1

Base design features

by Short time reaction
Optimization with
+ Optimization tool
„First in Chain!“

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 18 ( 21 )

 Education

Process Management
• Opti  CAD  CAE First in Chain!

CAE: Optimization
• Take the lecture! What structure do we really need?
• Improve process
• Persuade people

All
• Update ‚Engineering Judgement‘
• No ‚Design by Rules‘
•  ‚Design by Need‘

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 19 ( 21 )

 Final Message

Optimize !

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 20 ( 21 )

 Thank You!

Dr. D. Sprengel 6/2007 Topology Optimization of EMS Bracket 21 ( 21 )