Abstract: This paper aims to present the application of shape optimization to improve the design at critical locations on multiple components of automotive engines and drive units for electric vehicles.
Engine and drive unit castings require fatigue analysis to evaluate the durability for validation of the design. Many time-consuming design iterations may be needed to improve the design at geometrically sensitive locations of the component before arriving at a solution.
The author used the Tosca Shape Controller algorithm to solve the problem in multiple projects at various fillets and undercuts. Tosca software coupled with Abaqus and fe-safe helped achieve counter-intuitive solutions to complex issues. Shape optimization using Tosca has helped to reduce the design cycle time.
Keywords: Engine casting components, Drive unit, TOSCA, Shape Optimization, Counter intuitive design
Biography: Ramachandra K N has 20 years of industry experience, started his career with Avasarala Automation Limited in 1999 as Project Engineer. Later he joined Cummins India Ltd and worked for four years in Research and Development Applied Mechanics as Executive Manager. He joined Tata Consultancy Services Ltd in the year 2008, working for a Global Automotive OEM as Delivery Manager in his current role and works with them for various technical requirements which can be addressed using SIMULIA products. He has a Master's Degree in Machine Design from BMS College of Engineering, Bangalore. His focus areas are Optimization, Automation, and Durability Analysis.
