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Re Design of A Failed Clutch Fork Using
Re Design of A Failed Clutch Fork Using
Re Design of A Failed Clutch Fork Using
Technical Report
a r t i c l e i n f o a b s t r a c t
Article history: This paper presents a framework for re-designing a failed automotive component subjected to cyclic
Received 19 October 2009 loading. In the automotive industry, some parts fail before completing their design life. These failed
Accepted 6 January 2010 components have to be re-designed using modern optimisation tools. In this paper, a failed clutch fork
Available online 14 January 2010
was completely re-designed using topology and the shape optimisation approach. Stress-life fatigue anal-
ysis was conducted to correlate the crack location between the failed component and the simulation
model. A new design proposal was determined with the topology optimisation approach, and then design
optimisation by response surface methodology was effectively used to improve the new clutch fork
design. The mass reduction obtained was 24%. A maximum stress reduction of 9% was achieved, and
the rigidity was improved up to 37% in comparison to the original clutch fork.
Ó 2010 Elsevier Ltd. All rights reserved.
0261-3069/$ - see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2010.01.002
N. Kaya et al. / Materials and Design 31 (2010) 3008–3014 3009
model are shown in Fig. 6a, which shows the predicted life. As
shown in Fig. 6, the stress-life approach predictions are very rea-
sonable and show good correlation with the area of failure. The
failed clutch fork was taken from a vehicle service department,
and any information about its service history was not available;
therefore, the correlation of cycles to failure could not be found.
Fig. 6. (a) Crack initiation analysis results (53,5000 cycles); (b) Failed clutch fork.
N. Kaya et al. / Materials and Design 31 (2010) 3008–3014 3011
Here, q, qi and q0 are the normalised, intermediate and real mate- Longitudinal symmetry is defined on the part for topology
rial density parameters, respectively. Ei and E0 are the intermediate optimisation.
and real Young’s moduli, respectively, and n is an exponent. De- The design and non-design spaces are defined as shown in
tailed information about topology optimisation can be found in Fig. 7. Non-design space remains as it is during topology optimisa-
[19]. tion. The optimisation target is the maximisation of the stiffness
A concern in topology optimisation is that the design concepts with a volume reduction of the fork to 50%. The optimised material
developed are very often not manufacturable. The clutch fork con- distribution is shown in Fig. 8. Topology optimisation has the ten-
sidered in this study is to be designed as a casting. In the casting dency to create design proposals where material is accumulated in
process, cavities that are not open and lined up with the sliding the outer border areas of the design space. It can be seen that these
direction of the die are not feasible. Designs obtained by topology two arms have the same I-type cross section, and a substantial
optimisation often contain cavities that are not viable for casting. amount of material has been removed from the design space.
Transformation of such a design proposal to a manufacturable de- The next step in the development of a new clutch fork is the
sign can be extremely difficult, if not impossible. determination of the approximate shape from the result of the
In this paper, the draw direction option is used as a manufactur- topology optimisation, which serves as a design draft for the crea-
ing constraint. In this way, the material layout produced can be ori- tion of a new FE model for the subsequent simulation calculation
ented to a particular direction. Split casting, where the moulds are and shape optimisation. Fig. 9 shows the new geometry based
removed from either side of the casting, allows only cavities that upon the results of the topology optimisation.
are open and aligned with the sliding direction of the die. Split- For this phase of the design process, stress analysis verification
die draw direction constraints are applied in the direction of the was performed to accurately predict the performance of the new
z-axis. The other option used in this study is one plane symmetry. design.
The same boundary conditions and element size were applied
to the new designed clutch fork model. The von-Mises stress distri-
bution is shown in Fig. 10. Stress analysis results show that the
maximum von-Mises stress value is about 186 Mpa, which is lower
than the stress of the failed model. The maximum stress is found
near bearings, as shown in Fig. 10. Comparison of the original
Fig. 7. Design and non-design spaces on the finite element model. Fig. 9. New design of the clutch fork.
Altair HyperStudy is used in this study for response surface Based on the DOE results in Table 2, the response surface model
analysis and shape optimisation. It is general-purpose software for volume and maximum von-Mises stress were constructed using
used to study the behaviour of CAE models using design of exper- a quadratic polynomial as follows (x: shape1, y: shape2).
iment (DOE), optimisation and stochastic techniques. HyperMorph
is a part of Altair HyperMesh and is used as a pre-processor for volume ¼ 40227:5 þ 1654:6x þ 4368:9y þ 8:22x2 0:01y2
generating shape variables. Morphing is used for changing geome- 144:1xy
try by moving the group of nodes of a FE-mesh. Nodes are grouped
into clusters to reduce the number of design variables. No re-
meshing is required, and possible changes in the geometry are lim- maximum von-Mises stress ¼ 198:4 24:2x 29:9y þ 4:5x2
ited by element criteria for the FEM (warping angle, aspect ratio, þ 2:7y2 þ 9:6xy
etc.).
Morphing techniques attempt to transform one shape to an-
other by changing the finite element node coordinates. All nodes The response surface for the maximum von-Mises stress can be
affected by a change in shape are transformed. A shape parameter seen in Fig. 12.
will typically require the modification of several node coordinates The design optimisation is thus based on the response surface of
at the same time. The change in nodal coordinates associated with objectives and constraints. The optimisation problem therefore
a shape parameter is called a shape vector. Morphing techniques becomes:
are well suited for infinitesimal changes in shape parameters.
Table 3
Morphing was performed, and each morphed shape was saved
Results of shape optimization.
as a shape. Each saved shape was then assigned to a design vari-
able. In this study, the design variables were selected as two main Volume (mm3) 43,576
Maximum von-Mises stress (MPa) 175
dimensions of the I-type cross section, as shown in Fig. 11.
Shape1 0.39
In a DOE, each variable or factor is assigned a range, defined Shape2 0.62
with minimum and maximum values, and is usually normalised
as 1 or +1 (shape variables). The DOE table then defines the
points that should be used to create the response surface.
According to full factorial design with four factor levels and two
factors, 42 = 16 runs are executed, and the results are shown in Ta-
ble 2.
Table 2
Full factorial design table.
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References