Strategy Development of Structural Optimization in Design Processes

This thesis aims toward developing strategies in the area of structural optimization and to implement these strategies in design processes. At GM Powertrain Sweden where powertrains are designed and developed, two designs of a differential housing have been chosen for this thesis. The main tasks have been to perform a topology optimization of a model early in a design process, and a shape optimization on a model late in a design process. In addition the shape optimization strategies have also been applied on a fork shifter. This thesis covers the theory of different optimization strategies in general. The optimization processes are explained in detail and the results from the structural optimization of the differential housings as well as the fork shifter are shown and evaluated. The evaluation of the thesis provides enough arguments to suggest an implementation of the optimization strategies in design processes at GM Powertrain. A Structural Optimization group has great potential of closing the gap between structural designers and structural analysis engineers which in long terms mean that better structures can be developed in less time. To be competitive in the automotive industry these are two of the most important factors for being successful