Topology Optimization of Driveline Trunnions Using SIMULIA Tosca Structure and Abaqus

Abstract: Weight reducti

on in the vehicle industry is an essential measure to increase vehicle efficiency and reduce material, manufacturing costs, and emissions. This also becomes essential for VA/VE activities where already proven products are driven by well-defined load cases & already mapped through physical and virtual validation. Topology optimization has established itself as an innovative way for weight reduction, especially for casting parts. This paper presents the Topology optimization using Tosca Structure and Abaqus for driveline Trunnion castings. The objective was to minimize the mass considering given stiffness demands formulated using geometrical manufacturing constraints and casting feasibility simulation. A total weight saving of 27% was achieved using optimization.
Keywords: topology optimization; manufacturing constraints; design; virtual validation; casting feasibility.

Biography: Bapusaheb Rautray has worked with DANA India Technical Centre Private Ltd. for nine years. He started as a mechanical engineer with Safran Engineering Services, Bangalore. He has also worked with Mahindra & Mahindra, Kandivali in the Farm division. In his current role as a Project Leader, he is leading Simulation Projects in Off-highway applications. His areas of expertise include Durability, Optimization, Automation, and NVH. He has a master's degree (M.Tech) from IIT, Kanpur in Mechanical Engineering, specializing in Manufacturing Science.