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Welcome !

Dr. Rainer Meyer-Pruessner

1st European Hyperworks Technology Conference 2007

October 23rd 24th, 2007 Berlin, Germany

Significant Weight Reduction by Using Topology Optimization in Volkswagen Design Development

with emphasis on engine design Part 2

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Topology Optimization at Volkswagen

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Agenda
o Selection of optimized components o Topology design development of an air-conditioner bracket in 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 application o 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

water-pump wheel

deflection pulley

Installation position of bracket

crankshaft

design space of bracket

electric air-conditioner compressor

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Topology Optimization at Volkswagen

Topology Optimization of an air-conditioner bracket

Design objective: minimum weight and highest load carrying capacity

Design proposal from Topology Optimization: mass 1160 g

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Design proposal from external supplier made by intuition: mass 691 g

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Topology Optimization at Volkswagen

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Topology Optimization of an air-conditioner bracket

0.023 mm.

0.068 mm.

0.061 mm.

0.0052 mm.

Topology-model

force acting on deflection pulley

Model by external supplier

Comparison of deformation

Lack of stiffness of intuition-model

Displacement of compressor is much too large in the case of intuition-model
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Topology Optimization of an air-conditioner bracket

Displacement of compressor (in mm.)
Force direction X Y Z Deflection pulley Design space model 0.0078 0.00088 0.003 0.0027 Topologymodel 0.02 0.0027 0.00089 0.0052 Intuitionmodel 0.35 0.013 0.0062 0.061 New design 0.036 0.0034 0.0014 0.0081

Bracket weight: Topology-model: 1044 g Intuition-model: 691 g

Bad acoustic performance of the intuition-model is expected

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

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Topology Optimization at Volkswagen

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Topology Optimization of an air-conditioner bracket

Intuition-model: mass 691 g

The Topology model was chosen although it was heavier

Topology proposal: mass 1160 g

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New design: mass 1044 g

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Topology Optimization of an air-conditioner bracket

Touareg (projected)

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Topology Optimization at Volkswagen

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Increasing stiffness of a chain case

Original model Optimized model Ribs

Topology model

To reduce vibration of the cover, this design is proposed by Topology (bead) Optimization. Material: Magnesium

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Topology Optimization at Volkswagen

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Increasing stiffness of a chain case

Original model 1. Mode Undeformed Deformed

Optimized model 1. Mode Undeformed

23. October 2007 Topology Optimization at Volkswagen

Deformed
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Increasing stiffness of a chain case

Installation position of chain case
Purpose To modify the design of the chain case cover so that the natural frequencies reach maximum values for good acoustic performance

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Topology Optimization at Volkswagen

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Increasing stiffness of a chain case

4000 3500

For 1st mode

3000

f original = 1546 Hz f optimized = 2265 Hz 46.5% increase

Frequency (Hz)

2500

2000

Original model Optimised model

1500

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

1000

500

0 1 2 mode 3 4

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Increasing stiffness of a chain case

EOS (projected)

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Topology Optimization at Volkswagen

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Bead design on a sealing element

Design space

First eigenmode

Design objective: Increase of natural frequencies

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Bead design on a sealing element

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

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

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Bead design on a sealing element

Final design:
Sheet metal thickness: 1 mm Steel: 190 g

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Bead design on a sealing element

Design space 1. Mode 2. Mode 3. Mode 848 1056 1642

Proposal of Final Design ImproveOptimiment in % zation 1740 1510 78 2150 2790 1778 2421 68 47

Results of optimizing the natural frequencies (in Hz)

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Bead design on a sealing element

Installation position of sealing element

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Topology/ Shape Optimization of an engine sector

Load case: Ignition pressure

Cut out

Critical areas: stresses too high Bearing pedestal

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Topology/ Shape Optimization of an engine sector

New design Result of optimization

Stress reduced by 10 %. This version was produced.

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Area was defined by 19 design variables

Topology Optimization at Volkswagen

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Topology/ Shape Optimization of an engine sector

New idea for improving the structure 1. Original
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2. Add material where possible 3. Topology Optimization removes excess mass, and makes a proposal 4. Proposal transformed into new design

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Topology Optimization at Volkswagen

5. Added mass: 560 g

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Topology/ Shape Optimization of an engine sector

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

Components that have been optimized
Combined brackets for alternator, air-conditioning compressor, steering pump, Engine brackets Torque reaction mountings fan-, cooler-, air intake pipe supports exhaust manifold supports case for chain drive plastic suction pipe parts of cylinder block deflector ramp for crash condition control arms roller finger follower for valve gear Bead Optimization: sheet metal shields and -supports, oil sumps
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Consequences of weight reduction Benefits

- Lower fuel consumption - Material costs are reduced, but counterbalanced by costs to make the part suitable for manufacturing - Preserving resources

X X

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

Combined bracket for New Beetle

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Consequences of weight reduction

Lower fuel consumption
100 kg* reduction saves 0.35 l / 100 km

(= gain of 0.85 mpg)

and 8.4 g CO2/km or to decrease 1g CO2/km reduce weight -12 kg
* Reference car with 1300 kg

car body engine suspension equipment electr. components

Other parameters infuencing fuel consumption: Rolling resistance Aerodynamic resistance Electricity consumption
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Contribution to vehicle weight

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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 justifiable vehicles 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 to the final success. --------------------------

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

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