Lightweighting Case Studies



Topology optimization of a stamped steel to cast aluminum conversion

Customer Request
Reduce weight of stamped steel vehicle component utilizing lighter weight materials and engineering optimization techniques.

Optimal Approach
Utilizing topology optimization, Optimal identified the high stress points for the component to determine design iterations that would reduce mass before considering lighter weight materials. A specific aluminum alloy was selected as a replacement for stamped steel. Further optimization of component structure was conducted to ensure component integrity based on material trade-offs including hardness, stress strain curve, thermal conductivity.

The Resulting Benefits of Lightweighting Optimization:
  • Reduced component mass by 51%
  • Reduced material cost
  • Reduced complexity of component shape and manufacturing process
Lightweighting Topology Optimization

CAE Engineering Optimization - Crossmember

CAE Engineering Optimization - Crossmember

Background and Objective
Back-of-cab crossmember was found to develop cracks during durability testing.

Results - Baseline
Maximum von Mises stress of 754 MPa was observed during FE simulation.

Stress areas above yield of the material correlated with areas where the cracks formed during durability testing.

Design Optimization - Proposal I
Topology optimization resulted in design shown.

Stress analysis resulted in a maximum von Mises stress of 633 MPa.

Design Optimization - Proposal II
New design space defined.

Stress analysis resulted in a maximum von Mises stress of 427 MPa.

Summary of Results

Share This: