Optimizing Knuckle Design with Midas NFX
In the realm of automotive engineering, where various components endure diverse loads, Knuckle plays a pivotal role. It is subjected to significant demands for design optimization, aiming to ensure excellent rigidity while simultaneously reducing weight.
midas NFX offers a solution through topology optimization analysis, enabling the derivation of an optimal design while securing rigidity. However, for topology optimization analysis, a separate model for optimization needs to be created, diverging from the conventional Knuckle model.
This deviation is necessitated by the requirement of a design domain to explore new forms for optimization analysis. The optimization analysis model is then subjected to seven different loads experienced by the actual Knuckle to perform the topology optimization analysis.
To derive a design that ensures rigidity, constraints are set in terms of stress. This facilitates the output of an optimal design where specific stresses remain below predefined limits. Additionally, considering the manufacturing process of the actual product, manufacturing conditions are also applied.
The analysis results in the generation of a new Knuckle shape, serving as the basis for the designer to finalize the form. Structural analysis is conducted based on both the initial and optimized models to evaluate the effects on weight and rigidity aspects.
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It was observed that the optimized design exhibits an average 39% reduction in stress across all seven load conditions compared to the initial model. However, the weight of the final design experiences a marginal reduction of within 5% compared to the initial model. This marginal reduction is attributed to adhering to minimal manufacturing constraints.
midas NFX not only provides topology optimization analysis but also offers size optimization analysis capabilities. Leveraging these functionalities, designers can secure the optimal design directly from the analysis results.
By integrating midas NFX into the design process, automotive engineers can efficiently achieve lightweight, rigid, and optimized Knuckle designs, ensuring enhanced performance and efficiency in automotive applications.