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Finding the right balance between structure mass and geometry design has become of major importance in order to insure optimum product lifetime and cost. So, based on a plastic air shroud used in automotive engine cooling systems as object of study, this work shows a process that allows to find an optimized structure shape and adjust its thicknesses to guarantee the desired mechanical performance with a minimum mass, always taking into account the thickness range recommended for the injection process. The shroud is submitted to a dynamic load under a given frequency in which it must not present resonance. This behavior is represented in a finite element model through normal modes results. Finally, geometric parameters got from this experience can help designers to start future projects focused on the results that really make the difference concerning the mechanical behavior.

Considering the competitiveness of current automotive market, the search for low cost solutions that fulfill quality demands becomes essential to product development processes. A great issue in engine mount design consists of obtaining optimized geometrical shapes, maintaining component quality as well as complying with project requirements. In this work, an analysis is proposed to optimize the engine mount differential side of a commercial vehicle; all project steps for this component are also presented. A comparison between the try-error method and the topologic optimization method (TOM) was made, both using the finite-element method (FEM). The TOM has proved to be a powerful tool for optimizing geometry in a variety of engineering problems. Afterwards, the resulting geometry of TOM will undergo a yet more accurate optimization process, using the engine mount geometrical shapes as design variables.

This paper came from the latent needs of the Brazilian Market for products more robust and at the same time cheaper. With these needs in mind the product development team of General Motors do Brasil have developed together with Altair Engineering do Brasil a design methodology based on the topologic optimization technology. The objective of this paper was defined in a meeting of the technical teams of the two companies: Develop the application of the topologic optimization technology on design of structural components using actual GMB models. This methodology is described on this paper with some practical examples where it was applied. One the important news here presented it was considering the casting constrains that leave to an optimal design that can be produced. The results here presented were obtained using optimization and compared with the traditional approach here defined as try-error.

In a traditional finite element analysis, any change in the parameters that define the geometry or the physic properties requires a new analysis “run” in order to check the component performance. This can be a limitation in the ability of Engineers to conduct a what-if study, mainly when several input variables can be changed, that would require a large number of analyses, since the number is an exponential function in terms of variables. This work tries to explain what the Variational Technology is and how this is used to find an optimized automotive component design. The theory of this methodology is shown and some example where it has been applied is discussed. This Technology helps the Engineer during the design phase by using a series expansion that generate a response surface, where the Engineer can easily find the best design for each objective. The results are calculated in a single analysis using very accurate approximation functions.