Topology Optimization of Castings

Transcription

1 Topology Optimization of Castings 12/6/07 Martin Risberg Research Engineer, Product and Process Technology

2 Abstract In a R&D project Swerea SWECAST* has worked close to the Swedish industry to establish foundation of knowledge for volume- and weight-intelligent solutions of advanced cast components. The project has worked with products used by the heavy truck industries, wheel loaders, etc. The overall purpose was lower weight on components. The goal is to create more knowledge through the whole product chain; from design, choosing material, manufacturing, heat treatment and machining. In the project Topology Optimization with Altair OptiStruct has been used on a number of components in order to reduce weight. Involved industry partners are: Indexator AB, HIAB AB, Scania and Volvo 3P. A working method for optimization of cast components has been implemented in the product development process. A Volvo component developed with this process is on the market; used by both Volvo and Renault trucks. Scania is performing rig test on one if the two new designs. HIAB and Indexator are soon launching new topology optimized designs in the production. * Swerea SWECAST is the Swedish Institute of Casting Technology 2

3 Presentation Outline Presentation of Swerea SWECAST The project Virtual Product Development Case Studies Conclusion 3

4 Presentation of Swerea SWECAST The Swedish cast industry's research and educational Institute of Cast Technology. Develops product, material, process and environmental technology for cast metals. One of Europe's largest research groups with focus on cast components in cooperation with Jönköping University School of Engineering. Part of the Swerea Group. 4

5 Project Weight and Volume Intelligent Advanced Cast Components Establish foundation of knowledge for weightand volume-intelligent solutions of advanced cast components. The overall purpose is lowering weight. The goal is to create more knowledge through the whole product chain; from design, choosing material, manufacturing, heat treatment and machining. In this project Topology Optimization with Altair OptiStruct has been used on a number of components. 5

6 Virtual Product Development of Cast Components Design & Simulation Final Optimal Design Topology Optimization Design Design & Simulation Process Optimization Shape Optimization Flow Solidification Stress 6

7 Case Studies HIAB Slewing house Indexator Quick coupler Scania Beam Scania Engine bracket Volvo Wheel suspension bracket 7

8 Case Study - Slewing house on mobile crane Next generation mobile crane. 12 load cases in the simulation. Adjacent components modeled rigid. 8

9 Case Study - Weight reduction with 9%. Increased crane lift capacity with 3%. Stress reduction Original design 146 kg Design space Topology Optimization Result New design 134 kg 9

10 Case Study - Quick coupler on Rototilt Next generation coupler. 10 load cases in the simulation. Adjacent components modeled rigid. 10

11 Case Study - From welded to cast design. Weight reduction with 10%. Cost reduction - Increased number of variants from the same cast. Original design Design space Topology Optimization Result New design 11

12 Case Study - Beam Lighter weight giving a more energy-efficient truck with less fuel consumption. 4 load cases used in the simulation. Adjacent components modeled linear elastic. 12

13 Case Study - Weight reduction with 20%. Fatigue life simulated. Original design 15 kg Design space Topology Optimization Result New design 12 kg 13

14 Case Study - Engine bracket Lighter weight giving a more energy-efficient truck with less fuel consumption. 6 load cases used in the simulation. Adjacent components modeled linear elastic. 14

15 Case Study - Weight reduction with 27%. Reduced number of bolts. Rig test is in progress. Original design 6.8 kg Design space Topology Optimization Result New design 5.0 kg 15

16 Case Study - Wheel suspension bracket Lighter bracket giving more energy-efficient truck with less fuel consumption 4 load cases in the simulation. Adjacent components modeled linear elastic. 16

17 Case Study - Weight reduction with 6.0%. Significantly increased fatigue life time in test rig. Original design 29.9 kg Design space Topology Optimization Result New design 28.1 kg 17

18 Conclusion All products in this case studies have become lighter with the same or better performance. Altair OptiStruct is an useful tool for product development of cast components. The industry partners is now using topology optimization in their development phase. Swerea SWECAST is promoting topology optimization in the Swedish foundry industry and their customers. 18

19 Questions? 19

20 Thank you for your attention! Swerea SWECAST AB P.O. Box 2033, SE Jönköping, Sweden