Durability-based shape optimization with application to a steering system

Abstract

An optimization process which permits a durability-based shape optimization is presented. The process allows structural modifications in the simulation of an elastic multibody system to be taken into account. An introduction is provided to the theoretical basics of the methods used. The process control and the tools used to carry out the optimization process are explained. The application of the process is demonstrated through the example of a steering system. The necessary component models of the steering system, modelled by an elastic multibody system, a finite element analysis and a durability analysis, are presented and their quality is checked by means of comparison with test results. A durability-based shape optimization is carried out in order to increase the lifetime of the steering system housing.

Keywords:

• shape optimization
• durability analysis
• elastic multibody system
• steering system

Acknowledgements

This work has been supported by the company ZF Lenksysteme GmbH in Schwaebisch Gmuend, Germany. The support of the whole CAE-department headed by Johannes Fauser, especially of Dr Jens Pfister, is gratefully acknowledged.