OPTIMUM DESIGN OF THERMO-PLUNGER SUPPORT IN COMMERCIAL VEHICLES BY USING STRUCTURAL DESIGN AND FINITE ELEMENT METHODS

Abstract

This paper focuses on creating an optimum design and development of thermo-plunger parts for commercial vehicles in order to save material, reduce mass and make more sustainable automobiles. In this paper, natural frequency analysis, topology, and topography optimization methods have been used to create a new design for the thermo-plunger part. Thermo-plunger means an electric heater that is used for heating the inside of automobiles effectively and quickly and providing customer thermal comfort. It is positioned in the vehicle body, and its support parts have been developed by structural optimization techniques because there is not enough space in the engine compartment for automatic transmission commercial vehicles. The aim of this study is to make a lightweight and reinforced thermo-plunger support part design. Initially, a draft design was created in 3D model software. After that, topology and topography optimizations were applied on this draft design. At the end of studies, a final optimum support design has been obtained. The final design is 41.1% lighter than the initial design. At the same time, above 50 Hz natural frequency value has been obtained on the final design to avoid resonance problems. 

Keywords

• Optimum Design
• Topology Optimization
• Topography Optimization

Yapısal Tasarım ve Sonlu Eleman Metodlarını Kullanarak Ticari Araçlardaki Termo-piston Destek Parçasının Optimum Tasarımı

Abstract

Bu makale, malzemeden tasarruf etmek, kütleyi azaltmak ve daha sürdürülebilir otomobiller yapmak üzere ticari araçlar için optimum bir termo-piston parçası tasarımı ve geliştirilmesine odaklanmaktadır. Bu makalede, termo-piston parçasında yeni tasarım oluşturmak için doğal frekans analizi, topoloji ve topografya optimizasyon yöntemleri kullanılmıştır. Termo-piston, otomobillerin içini etkin ve hızlı bir şekilde ısıtmak için kullanılan ve müşteriye ısıl konfor sağlayan elektrikli ısıtıcı anlamına gelir. Bu parça araç gövdesinde konumlandırılmış olup, otomatik şanzımanlı ticari araçlar için motor bölmesinde yeterli alan olmadığı için destek parçaları yapısal optimizasyon teknikleri ile geliştirilmiştir. Bu çalışmanın amacı, hafif ve güçlendirilmiş bir termo piston destek parçası tasarımı yapmaktır. İlk olarak 3B modelleme yazılımında taslak tasarım oluşturulmuştur. Daha sonra bu taslak tasarım üzerinde topoloji ve topografya optimizasyonları uygulanmıştır. Çalışmalar sonunda nihai bir optimum destek parça tasarımı elde edilmiştir. Nihai tasarım, ilk tasarıma göre %41.1 daha hafiftir. Aynı zamanda, rezonans sorununu önlemek için nihai tasarımda 50 Hz'in üzerinde doğal frekans değeri elde edilmiştir

Keywords

• Optimum tasarım
• Topoloji optimizasyonu
• Topografya optimizasyonu

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