Shape Optimization of Engine Moving Components with Hyper-Study Integration

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Shape Optimization of Engine Moving Components with Hyper-Study Integration

  1. 1. April 23th, 2013Sangwoo, ChaShape Optimization of Engine Moving Componentswith Hyper-Study IntegrationHyundai·Kia Motors R&D CenterSession1: Optimization
  2. 2. Contents Introduction- Overview: engine moving components Shape Optimization of connecting rod- Analysis Procedure- Approach for weight reduction- Optimization results and shape Shape Optimization of engine piston- Analysis Procedure- Approach for weight reduction- Optimization results and shape Conclusion- Summary and conclusions
  3. 3. Overview: engine moving components Engine moving system- composed of Piston, Connecting rod, Crankshaft Role of piston and connecting rod- transferring force from expanding gas by firing to the crankshaft for making engine power Increasing needs for Optimization- CO2 emissions and cost down by weight reduction- frequently, failure occurrence by the hard condition according to the trend of high powerConnecting rod failure Piston failureConnecting rodPistonCrankshaftIntroduction
  4. 4. Contents Introduction- Overview: engine moving components Shape Optimization of connecting rod- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Shape Optimization of engine piston- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Conclusion- Summary and conclusions
  5. 5. Analysis Procedure Connecting rodFE model constructionOptimization definitionStructural analysisEvaluation: postprocessingOptimization analyze/resultOptimization(Iteration) Sensitivity through DOE Re-Optimization Optimization results and shapeSensitivityOptimized shape design Suggestion of design parameter Optimization shape designFatigueSafety Factor DeformationBucklingSafety Factor Simulation: 4 load case (batch job) Hypermesh Design variable: morphing Hyperstudy Objective function andrestraint definitionFEMFAT In-house S/WIn-house S/WAssemblyTension/Compression Buckling*ABAQUS
  6. 6. Evaluation item for durability Connecting rodIndirectevaluation ofbearing wearBucklingpredictionFatigue Safety Factor Big end Stiffness Buckling Safety FactorItemProblem/AnalysisresultEvaluation What: fatigue safety factor How: ratio of multi-axial stressamplitude and fatigue strength S/W: FEMFATFatigue failureprediction What: Big end deformation How: calculation at tensionloading by least square method S/W: In-house program What: Buckling due to highcombustion force How: Merchant-Rankine formula(considering eigenvalue, plastic) S/W: In-house programCriterion Sorry, it’s confidential
  7. 7. Connecting rodOptimization approach Optimization objective- Minimize current connecting rod weight Response and Constraint- Fatigue safety factor- Big end stiffness- Buckling safety factor Shape restraint- No interference with piston and cylinderblock at the dynamic motion- Limit of the manufacturing tool(ex. Curvature and angle of cutting tool)- No big change of the metallic patternCriterionsatisfactionPiston pinCrankshaftConnectingrodCapRod
  8. 8. Design variables: morphing shape Connecting rodSmall end diameter Small end thickness Shank width(outer)Shank width(inner) Shank thickness1 Shank thickness2*Outer *Inner(section) HyperMorph- definition of domain, handle- based on the design history(PROE) Design variables- total 6 shape variables Upper, lower bound- using sensitivity analysis(DOE)Domain, handleSmall endshankBig end
  9. 9. Connecting rodOptimization resultsObjective Weight 9%,ConstraintFatigue Safety FactorBig end stiffnessBuckling Safety FactorResponse Result11%,Same7%,Design variable historyFatigue Safety FactorBut, Criterion satisfactionBadGoodCurrent Optimization
  10. 10. Optimization shape Connecting rodOptimization processMeasuring dimension(optimization shape)CAD design(at the design team): Current: Change: Optimization
  11. 11. Contents Introduction- Overview: engine moving components Shape Optimization of connecting rod- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Shape Optimization of engine piston- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Conclusion- Summary and conclusions
  12. 12. Analysis Procedure PistonStructural analysisOptimization(Automation and Iteration) Stress analysis: ABAQUS s/wEvaluation: postprocessing Fatigue Safety Factor: FEMFAT s/w Mass center Extract (from ABAQUS *.dat)ABAQUS keyword:Mass center ofelement setReading safety factorfrom FEMFAT resultLoad and boundary conditionStress distributionFE model* temperature * profile: skirt,pin hole* Firing pressure,side force, inertia
  13. 13. Optimization approach Piston Optimization objective- Minimize current piston weight Response and Constraint- Fatigue safety factor: Criterion satisfaction- Piston mass center: +/- 5% change bound(no great difference in the dynamic characteristics) Shape restraint- No change of piston crown thickness(no great difference in the piston temperature)- Limit of the thickness for casting process* After optimization for weight reduction, dynamicanalysis is needed for dynamic characteristicsDynamic analysis(using PISDYN)Crown thicknessMass center
  14. 14. PistonDesign variables: morphing shapeRH thicknessUnder-crown area Bottom heightThrust thicknessLH thickness Oil drain height Oil drain thicknessA-thrust thickness Thrust skirt angle A-thrust skirt angleDomain, handle
  15. 15. PistonOptimization resultsObjective Weight 11%,ConstraintFatigue Safety FactorPiston mass centerResponse Result10%,SameBut, Criterion satisfactionObjective(weight) historyOptimization weightBadGoodFatigue Safety FactorCurrentOptimization
  16. 16. PistonOptimization shapeMeasuring dimension(optimization shape)CAD design(at the design team): Current : Change : OptimizationOptimization process
  17. 17. Contents Introduction- Overview: engine moving components Shape Optimization of connecting rod- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Shape Optimization of engine piston- Analysis Procedure- Approach for weight reduction- Result and Optimized shape Conclusion- Summary and conclusions
  18. 18. Conclusions Using the shape optimization techniques with Hyper-Study,1) for the connecting rod, a mass reduction of 9% was achieved.2) for the piston, a mass reduction of 11% was achieved.satisfying the restraint and manufacturing restriction Defining the design variables based on the PRO/E model history,the optimized shape was easily transferred to the CAD design. HMC has applied the optimization techniques using Optistruct,Hyper-study for weight reduction or durability increase of theother engine components.Summary and Conclusions
  19. 19. On going study..Crankshaft optimization: Current: Optimization* Substructuring method for solving
  20. 20. Thank you for your attention !!

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