Efficient Optimization Based on FEA and CFD Simulations

Weight reduction of a wheel carrier

Customer Request

The weight of an existing design of a wheel carrier had to be reduced. At the same time, the maximum stresses from misuse load cases as well as the local damage values should not be increased. The stiffness should not be reduced more than about 5%.

Our solution: topology optimization with Tosca Structure

Non parametric shape optimization using Tosca Structure.shape offered maximum freedom to solve the task. The consideration of manufacturing constraints was an important issue during shape optimization to ensure that the component could be manufactured by a casting procedure.

Benefit for the customer

A weight reduction could be realized considering all load cases of the different simulation disciplines simultaneously. Requirements for stiffness and durability could be guaranteed.