TOPOLOGY DESIGN AND MODAL ANALYSIS OF A BRACKET VIA FEA

The Engine in the vehicle is one of the most important components of on road vehicle such as car. High performance sports car has their engine component supported by the mounting bracket to its chassis frame. It plays a very much important role in improving the comfort & work environment of a car as well as the engine component. The improvement of the engine bracket system has been the subject of intense interest for many years. It is required to design the proper engine mounting bracket for a road vehicle. As such, the engine bracket has been designed as a frame work to support engine. Fatigue of engine mounting bracket has been continuously a concern which may lead to structural failure if the resulting stresses are high and excessive. Prolonged exposure to whole-body stresses in the working environment may lead to failure and in some cases it may damage the car. Therefore, the frequency of the bracket should be more than the engine frequency to avoid the resonance. The performance of selected materials with the help of modal analysis by using Finite element analysis

— The Engine supporting bracket plays a vital role by reducing noise, vibration and harshness. The current work describes the finite element approch for modal and static structural analysis of engine supporting bracket. CAD model of engine supporting bracket was created in CATIA software and same was analyzed for stress and vibration analysis using ANSYS workbench 15.0. Both initial design and modified design was compared for output responses in terms of equivalent Von-Mises stress, deformation and strain energy absorbed. In modal analysis, bracket was considered for vibration studies. The sole aim of modal analysis was to check whether the self excitation frequency of engine supporting bracket was less than natural frequency. Four alternative materials (Gray C.I., Aluminum alloy, Magnesium alloy and ERW-1) were analyzed. Stress analysis results suggest that deformation and Von-Mises stresses observed in EEW-1 materials was less (0.495 mm and 164.87 MPa). Further natural frequency of modified design was found to be 257.83 Hz which was well within the range below self-excitation frequency and less than the natural frequency (268.59 Hz) of initial design. It was found that aluminum bracket limit its use for the said application due to greater deformation and less stiffness. Magnesium bracket can be the option to ERW-1 steel for the Engine supporting bracket application but it cannot be deployed as it is highly susceptible to corrosion. From the results, it can be concluded that ERW-1 material best suit the requirement of the desired application and can be deployed with some safety standards.

International Journal of Engineering Applied Sciences and Technology, 2020

This paper deals with the topology optimization of the engine mounting bracket. The focus of this study is to reduce the weight of the bracket without compromising the structural characteristics. A small reduction in the weight of each bracket will have a great impact on the overall weight of the aircraft. Solid thinking Inspire is used for static analysis and topology optimization. The results of the von mises stress distribution and the displacement of the actual model and the optimized were compared. With the optimized model of engine mounting bracket, 51.25% weight reduction is achieved to maintain the same structural behaviour.

The engine mounting plays an important role in reducing the noise, vibrations and harshness for improving vehicle ride comfort. The first and the foremost function of an engine mounting bracket is to properly balance the power pack (engine &transmission) on the vehicle chassis for good motion control as well as good isolation. Present work deals with FEA analysis of engine mounting bracket. It includes the modeling of the engine mounting brackets by changing the material of component. Materials selected are Aluminum alloy and magnesium alloy. Analysis includes Static and Modal Analysis of engine mounting bracket using Square Cross section. The study shows that this bracket will have a dramatic weight reduction compare to standard aluminum alloy material and withstand high stress.

Bracket is one of the important components of an engine mount assembly, heavy performance truck has their engine supported by bracket and this engine mounting brackets assembly is used in chassis front frame which has been designed as a framework to support engine along with transmission member. The main function of the engine mount bracket is to properly balance the engine and transmission on the vehicle chassis, engine mount is an important part of the vehicle to reduce the vibration and noise, by which smooth ride of the vehicle can be achieved. Vibration and strength of engine bracket has been continuously a concern which may lead to structural failure if the resulting vibration and stresses are severe and excessive. The present work focuses on the FEA analysis of engine mount bracket for three materials by using meshing and analysis software which are HYPERMESH and ABACUS, the materials used are cast iron, wrought iron and mild steel, modal analysis and static analysis carried out by which maximum von-misses stress and natural frequency are computed. The main objective is to select the best material from the obtained result under prescribed conditions.

InImpact: The Journal of Innovation Impact, 2016

The design of critical components for aircrafts, cars or any other kind of machinery today is typically subject to two conflicting objectives, namely the maximisation of strength and the minimisation of weight. The conflicting nature of these two objectives makes it impossible to obtain a design that is optimal for both. The most common approach aiming for a single objective optimisation problem in aerospace is to maintain the weight minimisation as the objective, whilst setting strength requirements as constraints to be satisfied. However, manufacturing methods incorporate additional restrictions for an optimal design to be considered feasible, even when satisfying all constraints in the formulation of the optimisation problem. In this context, Additive Layer Manufacturing adds remarkably higher flexibility to the manufacturability of shape designs when compared with traditional processes. It is fair to note, however, that there are still some restrictions such as the infeasibility of building unsupported layers forming angles smaller than 45 degrees with respect to the underlying one. Nowadays, it is common practice to use a set of software tools to deal with these kinds of problems, namely Computer Aided Design (CAD), Finite Element Analysis (FEA), and optimisation packages. The adequate use of these tools results in an increase in efficiency and quality of the final product. In this paper, a case study was undertaken consisting of a turbine bracket from a General Electric challenge. A computational methodology is used, which consists of a topology optimisation considering an isotropic material at first instance, followed by the manual refinement of the resulting shape taking into account the manufacturability requirements. To this end, we used SolidWorks®2013 for the CAD, Ansys Workbench®14.0 for the FEA, and HyperWorks®11 for the topology optimisation. A future methodology will incorporate the automation of the shape optimisation stage, and perhaps the inclusion of the manufacturability restriction within the optimisation formulation.

IRJET, 2020

Topological optimization is a form of FEA method to reduce the compliances in structure based on the creation of a mathematical model. In this technique the material layout is optimized within sets of design constraints limit based on the feature of either Mass constraint Algorithms or Volume constraints Algorithm where the aim is to eliminate the stiff part of material which is assigned by pseudo density factor.

The design of critical components for aircrafts, cars or any other kind of machinery today is typically subject to two conflicting objectives, namely the maximisation of strength and the minimisation of weight. The conflicting nature of these two objectives makes it impossible to obtain a design that is optimal for both. The most common approach aiming for a single objective optimisation problem in aerospace is to maintain the weight minimisation as the objective, whilst setting strength requirements as constraints to be satisfied. However, manufacturing methods incorporate additional restrictions for an optimal design to be considered feasible, even when satisfying all constraints in the formulation of the optimisation problem. In this context, Additive Layer Manufacturing adds remarkably higher flexibility to the manufacturability of shape designs when compared with traditional processes. It is fair to note, however, that there are still some restrictions such as the infeasibility of building unsupported layers forming angles smaller than 45 degrees with respect to the underlying one. Nowadays, it is common practice to use a set of software tools to deal with these kinds of problems, namely Computer Aided Design (CAD), Finite Element Analysis (FEA), and optimisation packages. The adequate use of these tools results in an increase in efficiency and quality of the final product. In this paper, a case study was undertaken consisting of a turbine bracket from a General Electric challenge (Figure 5). A computational methodology is used, which consists of a topology optimisation considering an isotropic material at first instance, followed by the manual refinement of the resulting shape taking into account the manufacturability requirements. To this end, we used SolidWorks®2013 for the CAD, Ansys Workbench®14.0 for the FEA, and HyperWorks®11 for the topology optimisation. A future methodology will incorporate the automation of the shape optimisation stage, and perhaps the inclusion of the manufacturability restriction within the optimisation formulation.

As we know competitive pressure among the manufacturing organization is increasing day by day that is why the factors which attract mostly customers are comfort & cost. This work is consists of Finite Element Analysis (FEA) of steel bracket & a bracket made of material i.e. steel. The CAE tools used for this work are Solid work for modeling & ANSYS 19.2 for FE Analysis. The FE analysis of bracket is performed for the deflection, stresses and weight optimization. In ANSYS, the general process of FEA is divided into three main phases i.e., preprocessor, solution, and postprocessor. This model Of bracket of material i.e. (steel) is also prepared and analyzed by FEA which is then compare with the previous bracket with optimized bracket. The use of topology optimization technique then finds out weight reduction.

2020

1,2,3,4,5,6U.G, B.Tech Student, Department of Mechanical Engineering, MIT School of Engineering, MIT ADT University, Pune, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------Abstract – Topological optimization is a form of FEA method to reduce the compliances in structure based on the creation of a mathematical model. In this technique the material layout is optimized within sets of design constraints limit based on the feature of either Mass constraint Algorithms or Volume constraints Algorithm where the aim is to eliminate the stiff part of material which is assigned by pseudo density factor.

Proceedings of the International …, 2008

Structural optimization tools and computer simulations have gained the paramount importance in industrial applications as a result of innovative designs, reduced weight and cost effective products. Especially, in aircraft and automobile industries, topology optimization has become an integral part of the product design process. In this paper nonparametric topology optimization has been applied on a commercial aircraft vertical stabilizer component using ANSYS software. Suitable loads and constraints are applied on the initial design space of the component to accommodate for fin gust, rudder deflection, lateral gust, and other loads experienced by an aircraft during actual flight maneuvering. An integrated approach has also been developed to verify the structural performance and to overcome the problem of nonmanufacturable topology optimization results. Post machining distortions are also simulated by using element deactivation technique first by developing an initial residual stress field through Sequential Coupled Field analysis. CATIA is used to convert the optimized FE model into geometry based CAD model and then virtual machining is done. At the end topology assisted design model is compared with the actual part that is being manufactured for the aircraft. It is inferred that topology optimization results in a better and innovative product design with enhanced structural performance and stability.

Materials Today: Proceedings, 2018

An engine mount is a structure that holds the engine to the chassis.The engine mounting plays significant role in reducing the noise and vibrations for improving vehicle ride amenity. The Automobile engine chassis system may experience unwanted vibrations caused by interference between the road and the engine. Engine bracket has been designed as a structure to support engine. Due to vibrations of engine the holes on the engine Bracket get expanded which leads to the failure of bracket. This paper presents experimental and Finite Element analysis of a typical engine mounting bracket. In this paper we have explored usage of Modal Analysis in FEA to determine the frequency band and check the bracket for safety. Hence in this paper, we have undertaken experimental analysis for co-relation to establish variation of percentage and thus determine the nature of Boundary conditions to be used in FEA for more accurate analysis. Experimental analysis is done by Fast Fourier Transform analyzer. Finite Element analysis includes Static and Modal analysis using ANSYS15.0 which will determine natural frequency of engine bracket.

2016

In this study, designing accelerated life test system of 18m Euro VI commercial vehicle which was produced in Hexagon Studio, has been done model of these test system in virtual platform, doing analysis of these test system (simulation) and doing comparing studies both test results and analysis results. This study is aimed; create a faster methodology to define design of engine brackets, one of the parts of vehicle which is exposed to dynamic effects, in terms of strength. In this context; improving test and virtual engineering abilities and coordination of this subject with each other has been provided. Vehicle and road model has been verified with using road data’s which was taken in earlier tests. İn the second part; engine brackets fatigue life has been defined with using this data’s, verified models and finite element model. In the current product development process, it is impossible to do strength tests of vehicle which’s designs is not completes at all. With the end of this ...

2021

Nickel-based alloys are widely used for aerospace applications since they exhibit tremendous mechanical strength under extreme conditions. Additive manufacturing (AM), especially electron beam melting (EBM), technology is of interest due to its potential of direct digital manufacturing of highly complex fully functional light-weight critical components such as engine brackets. Most critical tasks of the brackets in their use, are to damper the vibration and support the engine weight. Consequently, it is desired simultaneously to reduce weight and maintaining good mechanical properties where the topology optimization is the right tool. In this study, the reference and weight-reduced brackets are fabricated via EBM method, and then followed by subjecting to the hot isostatic pressing (HIP) procedure. The engine bracket is weight reduced with a value of 32.08% utilizing a developed finite element analyses (FEA) based topology optimization. Furthermore, the effect of different loading c...

Engine mounts have an important function of containing firmly the power-train components of a vehicle. Correct geometry and positioning of the mount brackets on the chassis ensures a good ride quality and performance. As an FSAE car intends to be a high performance vehicle, the brackets on the frame that support the engine undergo high static and dynamic stresses as well as huge amount of vibrations. Hence, dissipating the vibrational energy and keeping the stresses under a pre-determined level of safety should be achieved by careful designing and analysis of the mount brackets. Keeping this in mind the current paper discusses the modeling, Finite Element Analysis, Modal analysis and mass optimization of engine mount brackets for a FSAE car. As the brackets tend to undergo continuous vibrations and varying stresses, the fatigue strength and durability calculations also have been done to ensure engine safety.