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Kostenstelle

04.10.2005, Kostenstelle, 1

Welcome ! Dr. Rainer Meyer-Pruessner OTC 05 September 27th – 28th, 2005 Optimization Technology Conference
Welcome !
Dr. Rainer Meyer-Pruessner
OTC 05
September 27th – 28th, 2005
Optimization Technology
Conference
Troy, MI, USA
Significant Weight Reduction by Using
Topology Optimization in Volkswagen
Design Development
with emphasis on engine design
27. September 2005
Topology Optimization at
Volkswagen
2

Kostenstelle

04.10.2005, Kostenstelle, 2

 

Agenda

     
 

o

How we started …

o

Example: design development of an engine bracket

 

o

Example: design development of a heat shield

o

Course of the design process

o

Selection of optimized components

o

Shape/ Topology Optimization of an engine sector

o

Areas of application

o

Consequences of weight reduction

 

o

Summary

27.

September 2005

Topology Optimization at Volkswagen

3

27. September 2005 Topology Optimization at Volkswagen 3
September 2005 Topology Optimization at Volkswagen 3 How we started … Engine bracket for T4 952

How we started …

Topology Optimization at Volkswagen 3 How we started … Engine bracket for T4 952 g 733

Engine bracket for T4

952 g
952 g
733 g
733 g

New design adapted to load condition, i.e. material is removed where not contributing to load carrying capacity

April 1997

27.

September 2005

Topology Optimization at Volkswagen

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where not contributing to load carrying capacity April 1997 27. September 2005 Topology Optimization at Volkswagen

Kostenstelle

04.10.2005, Kostenstelle, 3

Topology Optimization of an engine bracket Z Y X Principle configuration: Engine bearing – engine
Topology Optimization of an engine bracket
Z
Y
X
Principle configuration:
Engine bearing – engine bracket
Design objective:
engine bracket
as light as possible -
made from aluminium
27.
September 2005
Topology Optimization at
Volkswagen
5
Topology Optimization of an engine bracket Load impact Design space Forces applied: - on longitudinal
Topology Optimization of an engine bracket
Load impact
Design space
Forces applied:
- on longitudinal axis
- on vertical axis
Bolt-on points for engine block
- for assembly
27.
September 2005
Topology Optimization at
Volkswagen
6

Kostenstelle

04.10.2005, Kostenstelle, 4

Topology Optimization of an engine bracket Design proposal: Best material distribution under impact of all
Topology Optimization of an engine bracket
Design proposal:
Best material distribution under impact of all
forces & including manufacturing constraints,
i.e. demolding direction
Construction according to design proposal.
Suitability for casting must be taken
into account.
27.
September 2005
Topology Optimization at
Volkswagen
7

Topology Optimization of an engine bracket

Computer simulation of casting process. Foundry may demand modifications.
Computer simulation of casting process. Foundry may demand modifications.

Computer

simulation of

casting

process.

Foundry may

demand

modifications.

27. September 2005

Topology Optimization at Volkswagen

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of casting process. Foundry may demand modifications. 27. September 2005 Topology Optimization at Volkswagen 8 4

Kostenstelle

04.10.2005, Kostenstelle, 5

Topology Optimization of an engine bracket Max : 130 MPa Stress check of new design
Topology Optimization of an engine bracket
Max : 130 MPa
Stress check of new design
Local shape improvement still
necessary
27.
September 2005
Topology Optimization at
Volkswagen
9
Topology Optimization of an engine bracket Final design Stress reduction Thicker rib means: castable with
Topology Optimization of an engine bracket
Final design
Stress reduction
Thicker rib means:
castable with better
performance
27.
September 2005
Topology Optimization at
Volkswagen
10

Kostenstelle

04.10.2005, Kostenstelle, 6

Topology Optimization of an engine bracket AUDI A3 3,2 l V6 MPI 184 KW 27.
Topology Optimization of an engine bracket
AUDI A3
3,2 l V6 MPI 184 KW
27.
September 2005
Topology Optimization at
Volkswagen
11
Topology Optimization of an engine bracket Topology Optimization not correctly applied in model building and
Topology Optimization of an engine bracket
Topology Optimization not correctly applied in model building and in programme use:
mass = 987 g
mass = 1340 g
Result of external supplier
Our result
27.
September 2005
Topology Optimization at
Volkswagen
12

Kostenstelle

04.10.2005, Kostenstelle, 7

Topology Optimization of an engine bracket Topology Optimization not correctly applied : Max stress: 183
Topology Optimization of an engine bracket
Topology Optimization not correctly applied :
Max stress: 183 MPa
Mass: 1025 g
mass: 1120 g
Construction of external
supplier was not carried out
In comparison: Our
construction
27.
September 2005
Topology Optimization at
Volkswagen
13
Bead design on heat shield Position of the heat shield in the engine 27. September
Bead design on heat shield
Position of the heat
shield in the engine
27.
September 2005
Topology Optimization at
Volkswagen
14

Kostenstelle

04.10.2005, Kostenstelle, 8

Bead design on heat shield

D e s i g n s p a c e First eigenmode Design objective:

Design space

D e s i g n s p a c e First eigenmode Design objective: Increase

First eigenmode

Design objective: Increase of natural frequencies

27. September 2005

Topology Optimization at Volkswagen

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27. September 2005 Topology Optimization at Volkswagen 15 Bead design on heat shield Shape and position

Bead design on heat shield

Shape and position of beads: Proposal of Topography Optimization Input: 5 Eigenmodes & prescription of

Shape and position of beads:

Proposal of Topography Optimization Input: 5 Eigenmodes & prescription of a linear pattern

Input: 5 Eigenmodes & prescription of a linear pattern 3-D view of beads in IGES-format for

3-D view of beads in IGES-format for the performance of the CAD

27. September 2005

Topology Optimization at Volkswagen

16

view of beads in IGES-format for the performance of the CAD 27. September 2005 Topology Optimization

Kostenstelle

04.10.2005, Kostenstelle, 9

Bead design on heat shield Final design: Sheet metal thickness: 2 mm Aluminium: 184 g
Bead design on heat shield
Final design:
Sheet metal thickness:
2 mm
Aluminium: 184 g
27.
September 2005
Topology Optimization at
Volkswagen
17

Bead design on heat shield

 

Design

Proposal of

Final

Improve-

space

Optimi-

Design

ment in %

zation

1.

mode

585

705

643

10

2.

mode

590

725

676

15

3.

mode

628

804

735

17

4.

mode

727

952

900

24

5.

mode

826

1190

1036

25

Results of optimizing the natural frequencies (in Hz)

27. September 2005

Topology Optimization at Volkswagen

18

27. September 2005 Topology Optimization at Volkswagen 18

Kostenstelle

04.10.2005, Kostenstelle, 10

Bead design on heat shield Jetta 2,5 l R5 110 KW 27. September 2005 Topology
Bead design on heat shield
Jetta 2,5 l R5 110 KW
27.
September 2005
Topology Optimization at
Volkswagen
19

Design process

 
 

Topology Optimization

New developmental course

Topology Optimization incorporated into the developmental process

Given: Design space, loads, contraints

Topology Optimization

Contruction by CAD

Contruction by CAD

The length of the boxes symbolizes the time demanded for the performance of each task

Stress Analysis with Topology Optimization Stress Analysis without Topology Optimization

Stress Analysis with Topology Optimization

Stress Analysis without Topology Optimization

Design adjustment: Thickness of items, radii, Final component: Weight, stiffness and durability optimized

Design adjustment: Thickness of items, radii,

Final component: Weight, stiffness and durability optimized
Final component: Weight, stiffness and durability optimized

27.

September 2005

Topology Optimization at Volkswagen

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27. September 2005 Topology Optimization at Volkswagen 20

Kostenstelle

04.10.2005, Kostenstelle, 11

Selection of optimized components

Bracket for air-conditioning compressor

Original bracket 271 g
Original
bracket
271 g
Optimized design 225 g
Optimized
design
225 g

20% weight reduction

27. September 2005

Topology Optimization at Volkswagen

21

27. September 2005 Topology Optimization at Volkswagen 21 Selection of optimized components Touareg 2,5 l R5
Selection of optimized components Touareg 2,5 l R5 TDI 128 KW 27. September 2005 Topology
Selection of optimized components
Touareg 2,5 l R5 TDI 128 KW
27.
September 2005
Topology Optimization at
Volkswagen
22

Kostenstelle

04.10.2005, Kostenstelle, 12

Selection of optimized components

 

Combined bracket for alternator, air-conditioning compressor, and steering pump

 
2000 g
2000 g
2000 g 1550 g
2000 g 1550 g
1550 g
1550 g
2000 g 1550 g

Original shape

Design space

Topology result

New design

Stress check

27.

September 2005

Topology Optimization at Volkswagen

 

23

27. September 2005 Topology Optimization at Volkswagen   23

Selection of optimized components

Effect of manufacturing constraints: OFF ON Details of topology result for the bracket :

Effect of manufacturing constraints:

OFF

ON

Details of topology result for the bracket :

Effect of manufacturing constraints: OFF ON Details of topology result for the bracket :

27. September 2005

Topology Optimization at Volkswagen

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OFF ON Details of topology result for the bracket : 27. September 2005 Topology Optimization at

Kostenstelle

04.10.2005, Kostenstelle, 13

Selection of optimized components Multivan V6 3,2l 173 KW 27. September 2005 Topology Optimization at
Selection of optimized components
Multivan V6 3,2l 173 KW
27.
September 2005
Topology Optimization at
Volkswagen
25

Selection of optimized components

Deflector ramp

Deflector ramp US-NCAP* 35mph Frontcrash *New Car Assessment Program Vehicle front axle
Deflector ramp US-NCAP* 35mph Frontcrash *New Car Assessment Program Vehicle front axle
Deflector ramp US-NCAP* 35mph Frontcrash *New Car Assessment Program Vehicle front axle

US-NCAP* 35mph Frontcrash

*New Car Assessment Program

Vehicle front axle

27. September 2005

Topology Optimization at Volkswagen

26

Frontcrash *New Car Assessment Program Vehicle front axle 27. September 2005 Topology Optimization at Volkswagen 26

Kostenstelle

04.10.2005, Kostenstelle, 14

Selection of optimized components

 
 
 
 
 

Original shape: 992 g

Design proposal

Saving: 20%

Saving: 20%

Material: steel

AQ 250 transmission

 

Position of hole is very sensitive to stress

 

New design: 786 g

US-NCAP 35mph Frontcrash

 
 

27.

September 2005

Topology Optimization at Volkswagen

27

27. September 2005 Topology Optimization at Volkswagen 27

Selection of optimized components

 

Combined bracket for alternator and air-conditioning compressor

 
for alternator and air-conditioning compressor   Original shape Design space T o p o l o
for alternator and air-conditioning compressor   Original shape Design space T o p o l o
for alternator and air-conditioning compressor   Original shape Design space T o p o l o
for alternator and air-conditioning compressor   Original shape Design space T o p o l o
for alternator and air-conditioning compressor   Original shape Design space T o p o l o

Original shape

Design space

Topology

New design

Stress check

 

result

 

2018 g

1523 g

1698 g

 

27.

September 2005

Topology Optimization at Volkswagen

 

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27. September 2005 Topology Optimization at Volkswagen   28

Kostenstelle

04.10.2005, Kostenstelle, 15

Topology Optimization of an engine bracket PASSAT V6 3,6 l FSI 206 KW 27. September
Topology Optimization of an engine bracket
PASSAT V6 3,6 l FSI 206 KW
27.
September 2005
Topology Optimization at
Volkswagen
29
Selection of optimized components Combined bracket for alternator and air-conditioning compressor Original shape Design
Selection of optimized components
Combined bracket for alternator and air-conditioning compressor
Original shape
Design space
Topology
New design
Stress check
result
2058 g
1676 g
27.
September 2005
Topology Optimization at
Volkswagen
30

Kostenstelle

04.10.2005, Kostenstelle, 16

Selection of optimized components

Touran
Touran

2,0 l

FSI

110 KW

Touran 2,0 l FSI 110 KW Golf
Golf
Golf

27. September 2005

Topology Optimization at Volkswagen

31

27. September 2005 Topology Optimization at Volkswagen 31 Topology/ Shape Optimization of an engine sector Load
Topology/ Shape Optimization of an engine sector Load case: Ignition pressure Cut out Critical areas:
Topology/ Shape Optimization of an engine sector
Load case: Ignition pressure
Cut out
Critical areas:
stresses too high
Bearing pedestal
27.
September 2005
Topology Optimization at
Volkswagen
32

Kostenstelle

04.10.2005, Kostenstelle, 17

Topology/ Shape Optimization of an engine sector

New design

New design Stress reduced by 10 %. This version was produced. Result of optimization Area was

Stress reduced by 10 %. This version was produced.

Result of optimization

design Stress reduced by 10 %. This version was produced. Result of optimization Area was defined

Area was defined by 19 design variables

27. September 2005

Topology Optimization at Volkswagen

33

27. September 2005 Topology Optimization at Volkswagen 33 Topology/ Shape Optimization of an engine sector New

Topology/ Shape Optimization of an engine sector

New design Mesh refined. Stresses too high Design space Topology proposal Not possible to place
New design
New
design

Mesh refined.

Stresses too

high

Design space

Topology

proposal

refined. Stresses too high Design space Topology proposal Not possible to place stress constraints into a
refined. Stresses too high Design space Topology proposal Not possible to place stress constraints into a

Not possible to place stress constraints into a design area

Construction was not carried out

27. September 2005

Topology Optimization at Volkswagen

34

into a design area Construction was not carried out 27. September 2005 Topology Optimization at Volkswagen

Kostenstelle

04.10.2005, Kostenstelle, 18

 

Topology Optimization: Areas of application

   

Components

Combined brackets for alternator, air-conditioning compressor, steering pump, …

 

that have

 

been

optimized

Engine brackets Torque reaction mountings

fan-, cooler-, air intake pipe supports exhaust manifold supports case for chain drive plastic suction pipes

deflector ramp for crash condition control arms roller finger follower for valve gear

Bead Optimization: sheet metal shields and -supports, oil sumps

 

27.

September 2005

Topology Optimization at Volkswagen

35

27. September 2005 Topology Optimization at Volkswagen 35

Consequences of weight reduction

Benefits

Material costs

Benefits Material costs Lower fuel consumption Improvement vehicle driveability Suitable for manufacture X X X Combined

Lower fuel consumption

Improvement vehicle driveability

Suitable for manufacture

X X X
X
X
X

Combined bracket for New Beetle

In order to avoid casting defects we had to close 3 of 5 holes (X).

27. September 2005

Topology Optimization at Volkswagen

36

to avoid casting defects we had to close 3 of 5 holes (X). 27. September 2005

Kostenstelle

04.10.2005, Kostenstelle, 19

Consequences of weight reduction Lower fuel consumption 100 kg* reduction saves 0.35 l / 100
Consequences of weight reduction
Lower fuel
consumption
100 kg* reduction
saves 0.35 l / 100 km and
(= gain of 0.85 mpg)
Other parameters infuencing fuel
consumption:
8.4 g CO 2 /km
or
to decrease 1g CO2/km
reduce weight -12 kg
* Reference car with 1300 kg
Rolling resistance
Aerodynamic resistance
Electricity consumption
27.
September 2005
Topology Optimization at
Volkswagen
37

Summary

   

Topology Optimization incorporated into the design process means:

 

Conception of virtual vehicle

- Careful and accurate collection of load information is necessary

- Design decisions made by computational optimization

- Ensure durability by reliable calculation

- Do not dispense with experimental tests, but confine them to validate the final state

Reduce new product development time to market Lower costs Produce fuel-efficient and environmentally justifiable vehicles

Reduce new product development time to market Lower costs Produce fuel-efficient and environmentally justifiable vehicles

27.

September 2005

Topology Optimization at Volkswagen

38

27. September 2005 Topology Optimization at Volkswagen 38

Kostenstelle

04.10.2005, Kostenstelle, 20

Thank you very much. All the work involved was carried out in excellent co-operation with
Thank you very much.
All the work involved was carried out in excellent
co-operation with the computational department,
all design departments and the test center.
All staff members have contributed equally to the
final success.