Design and manufacturing of the powertrain mount for a next generation car
Area of expertise:
|Project period||2015 г.|
In 2015, IAMT (IAMT key subdivision is SPbPU Computer-Aided Engineering Centre of Excellence - CompMechLab®) carried out the complete works cycle involving design and manufacturing of a unique component of the next generation vehicle, that was the powertrain mount with best combination of structure weight, strength, functional characteristics, manufacturing technology.
CompMechLab® team competences and unique work experience in terms of world leaders of automotive industry orders provided record-breaking time of project implementation. The following took us just two months:
- Simulation-based design of the powertrain mount for a next generation domestic car; CAD-model development, as well as digital design documentation;
- development of finite element models for powertrain mount and structural elements (car body); all required calculation checks in terms of performance and structure strength, multivariate optimization of the powertrain mount by means of direct modelling;
- a small series of powertrain mount manufacturing, production adjustment.
World experts of automotive industry assessed that minimum weight of the powertrain mount with set characteristics was 12 kg. However, CompMechLab® specialists managed to develop the powertrain mount of 5.825 kg, which is significantly less than that of foreign origin, having applied a combination of topological optimization methods and bionic design principles.
Unique manufacturing technology based on the combination of topological optimization methods and bionic design principles considers all limitations applied to a structure. Thus, the powertrain mount with the best weight is an open-profile structure with stiffeners.
Design of the powertrain mount structure does not require any adjustments of parts, body assemblies, or hook-up elements. All required performance checks have been done, including sequence of car body structure assembly and elements assemblability.
Except for prototype design and manufacturing, powertrain mount small-scale serial production has been run using up-to-date hybrid manufacturing technologies (additive technologies + casting technologies).