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This paper describes the use of a frequency based fatigue calculation to evaluate the fatigue life of a brake shield subjected to a dynamic load, where the loading and response are categorized using Power Spectral Density (PSD) functions. Traditionally fatigue damage is associated with time dependent loading, usually in the form of stress or strain. However, there are many design scenarios when the loading, or fatigue damage process, cannot easily be defined using time signals. In these cases the design engineer usually has to use a test based approach to evaluate the fatigue life of his component. In this study the brake shield is tested on shaker table using PSD loads as per SSTS. The FE approach is correlated with the physical test. The design is optimized and analyzed in FE to ensure it satisfies the design requirements thus reducing the product development cycle.

In this publication, we want to present two examples to demonstrate how the SKO method can be used in practice. The SKO method is a tool for topological optimization and is based on the simulation of biological load carriers. The first example is an engine bracket which had to be optimized to reduce the maximum von Mises stress by a factor of at least 60%. The initial design of the bracket was a u-profile with some ribs inside. In the first step the arrangement of the ribs was optimized, which led to a stress reduction of 20 %. In the second step the cross section was optimized, leading to the desired overall stress reduction of 60%. Furthermore, the weight of the optimized design was reduced by nearly 25 % in comparison to the initial design. In the second example, the SKO method is used to create holes in the spoke region of a wheel-rim. The resulting new spoke design has a weight reduction of 26 % in this region in comparison with a production rim.