Track Bar Bracket Development with the Help of Advanced Optimization Techniques 2016-01-1387

The advanced Optimization techniques help us in exploring the light weight architecture. This paper explains the process of designing a lightweight track bar bracket, which satisfies all durability performance targets.

The mounting locations and load paths are critical factors that define the performance and help in the development of weight efficient structure. The process is to identify the appropriate bolt location through Design of Experiment (DOE) and topology based studies; followed by section and shape optimization that help to distribute material in a weight efficient manner across the structure. Load path study using topology optimization is performed to identify the load path for durability load cases. Further shape optimization is done using hyper study to determine the exact thickness of the webs and ribs. A significant weight reduction from the baseline structure is observed. This process may be applicable for all casting components.