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Kostenstelle 08.11.2007, Kostenstelle, 1

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Welcome !

23. October 2007 Topology Optimization at

Volkswagen

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1st EuropeanHyperworks Technology

Conference 2007

October 23rd 24th, 2007

Berlin, Germany

Significant Weight Reduction by UsingTopology Optimization in VolkswagenDesign Development

with emphasis on engine design

Part 2

Dr. Rainer Meyer-Pruessner


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Agenda

o Selection of optimized components

o Topology design development of an air-conditioner bracketin contrast to conventional design

o Increasing stiffness of a chain case

o Bead design of a sealing element

o Shape/ Topology Optimization of an engine section

o Areas of applicationo Consequences of light weight design

o Summary


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Selection of optimized components

Average mass reduction: 20%


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Topology Optimization of an air-conditioner bracket

belt tensioner

deflectionpulley

electric air-conditionercompressordesign space

of bracket

crankshaft

Installationposition of bracketwater-pump

wheel


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Design objective: minimum weight and highest load carrying capacity

Design proposal from TopologyOptimization: mass 1160 g

Design proposal from external suppliermade by intuition: mass 691 g



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0.023 mm.

0.0052 mm.

0.061 mm.

0.068 mm.

Topology-model - force acting on deflection pulley - Model by external supplier

Displacement of compressor is much too large in the case of intuition-model

Comparison of deformationLack of stiffness of intuition-model



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0.061

0.0062

0.013

0.35

Intuition-

model

0.00810.00520.0027Deflection

pulley

0.00140.000890.003Z

0.00340.00270.00088Y

0.0360.020.0078X

New designTopology-

model

Design space

model

Force

direction

Displacement of compressor (in mm.)

o The displacements of the Intuition-design are much larger compared to the New Design,which is made according to the Topology-model

o All stresses that occur are below 80 MPa in both models

o The first natural frequency of the intuition-design: 119 Hz;

of the topology-model: 315 Hz

Bracket weight:

Topology-model: 1044 gIntuition-model: 691 g

Bad acousticperformance of the

intuition-model isexpected



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New design: mass 1044 gTopology proposal: mass 1160 g


Intuition-model: mass 691 g

The Topology model waschosen although it washeavier


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Touareg (projected)


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Original model Optimized model

Ribs

Increasing stiffness of a chain case

To reduce vibration of the cover, thisdesign is proposed by

Topology (bead) Optimization.Material: Magnesium

Topology model


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Undeformed

Undeformed

Deformed

Deformed

Original model

Optimized model

1. Mode

1. Mode



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.

PurposeTo modify the

design of the chain

case cover so thatthe natural

frequencies reach

maximum values forgood acoustic

performance

Installationposition of chain

case



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For 1st mode

f original = 1546 Hzf optimized = 2265 Hz

46.5% increase

For 2nd mode = 57%For 3rd mode = 27%For 4th mode = 18%

0

500

1000

1500

2000

2500

3000

3500

4000

1 2 3 4

mode

Frequen

cy

(Hz)

Original model

Optimised model



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EOS (projected)


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Bead design on a sealing element

Design space First eigenmode

Design objective: Increase of natural frequencies


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Shape and position of beads:Proposal of Topography Optimizationwhen a circular pattern is prescribed

3-D view of beads in IGES-format inorder to perform CAD



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Final design:

Sheet metal thickness:1 mm

Steel: 190 g



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472421279016423. Mode

681778215010562. Mode

78151017408481. Mode

Improve-ment in %

Final DesignProposal ofOptimi-zation

Designspace

Results of optimizing the natural frequencies (in Hz)



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Installationposition of sealing

element


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Topology/ Shape Optimization of an engine sector

Bearing pedestal

Critical areas:stresses too high

Load case: Ignition pressure

Cut out


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Stress reduced by 10 %.This version was produced.

Area was defined by19 design variables

Result of optimizationNew design


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New idea for improving thestructure

1. Original

2. Add material wherepossible

3. Topology Optimizationremoves excess mass,and makes a proposal

4. Proposal transformedinto new design

5. Added mass: 560 g

1 2

3 4


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To upgrade an existing engine to higher power

only the required mass is added to the cylinder block.

The mass is placed exactly where it is needed.

Total stress reduction: 20%


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Topology Optimization: Areas of application

Combined bracketsfor alternator, air-conditioning compressor, steering pump,

Engine bracketsTorque reaction mountings

fan-, cooler-, air intake pipe supportsexhaust manifold supportscase for chain driveplastic suction pipeparts of cylinder block

deflector ramp for crash condition

control armsroller finger follower for valve gear

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

Componentsthat have

been

optimized


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Consequences of weight reduction

Benefits- Lower fuel consumption

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

XX

X

Combined bracket for New Beetle

- Material costs are reduced, butcounterbalanced by costs to makethe part suitable for manufacturing

- Preserving resources


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100 kg* reductionsaves 0.35 l / 100 km

(= gain of 0.85 mpg)and 8.4 g CO2/km

orto decrease 1g CO2/km

reduce weight -12 kg

* Reference car with 1300 kg

Other parameters infuencing fuel

consumption:

Rolling resistance Aerodynamic resistance Electricity consumption

Lower fuel

consumption

car bodysuspension

electr. components

engineequipment

Contribution to vehicle weight

Consequences of weight reduction


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Summary

Topology Optimization incorporated into the design process means:

Conception of virtual vehicle

- Careful and accurate collection of load information is necessary:Topology proposal is a direct consequence of load impact

- Design decisions are made by computational optimization

- Ensure durability by reliable calculation

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

o Produce fuel-efficient and environmentally justifiablevehicles

o Lower costs

o Reduce new product development time to market


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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 tothe final success.--------------------------

REF.: R. Meyer-Pruessner, The Topology Optimization at Volkswagen and its Introduction in theProcess of Engine Development, Opticon,Newport Beach, California, USA, 1999R. Meyer-Pruessner, Significant Weight Reduction by Using Topology Optimization in Volkswagen Design Development , OTC 05,Troy, Mi, USA, 2005

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