In vehicle design minimizing the weight of a component is doubly valuable. Beside the saved material the lighter design helps to reduce fuel consumption. Today, it is standard practice to use a combination of Finite Element Analysis (FEA) and numerical optimization methods to develop lightweight components. There are different methods to solve the optimization tasks. Topology optimization is used to find a first layout of the component geometry. In the design process this layout can be transformed to a CAD model. With a subsequent shape optimization extreme stress values can be reduced and stress distribution is smoothed. The paper shows the procedure for lightweight design of a gear wheel for a truck transmission in several steps. It also provides short information about a very easy way to specify shape basis vectors in the shape optimization as an example for advanced modelling capabilities. In addition, information about costs and the realised benefits are presented. The development departments have to take care of their budgets and have to justify the use of new design methods. In order to check the effect of using optimization methods for the design of the gear wheel the required working effort is compared with the weight reduction. The maximum weight reduction was achieved during topology optimization. Most of the gain is lost with the decision to forge the gear wheel. Mainly the region close to the hub, which is not accessible from both sides, is responsible for the added mass during transformation to a new CAD model. Although shape optimization has to decrease the stress peak from 162 % to the limit, a further reduction of mass was still possible. The mass reduction is about 25% all over the gear wheel. Considering just the design space, the mass reduction is more than 50 %. The effort needed for the complete optimization process is about 16 working days. The low time effort is mainly caused by the improved modelling tools, the improved algorithms and the growing experience in numerical optimization.


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    Titel :

    Weight optimization of a gear wheel considering the manufacturing process and cyclic symmetry


    Beteiligte:


    Erscheinungsdatum :

    2009


    Format / Umfang :

    10 Seiten, 10 Bilder, 1 Tabelle


    Medientyp :

    Aufsatz (Konferenz)


    Format :

    Print


    Sprache :

    Englisch




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