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Re-design of a failed clutch fork using topology and shape optimisation by the response surface method

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Kaya, Necmettin
Karen, İdris
Özturk, Ferruh

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Elsevier

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Abstract

This paper presents a framework for re-designing a failed automotive component subjected to cyclic loading. In the automotive industry, some parts fail before completing their design life. These failed components have to be re-designed using modern optimisation tools. In this paper, a failed clutch fork was completely re-designed using topology and the shape optimisation approach. Stress-life fatigue analysis was conducted to correlate the crack location between the failed component and the simulation model. A new design proposal was determined with the topology optimisation approach, and then design optimisation by response surface methodology was effectively used to improve the new clutch fork design. The mass reduction obtained was 24%. A maximum stress reduction of 9% was achieved, and the rigidity was improved up to 37% in comparison to the original clutch fork.

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Design, Improvement, Failure, Materials science, Automotive industry, Clutches, Surface properties, Topology, Automotive component, Crack location, Cyclic loadings, Design life, Design optimisation, Fatigue analysis, Mass reduction, Maximum stress, New design, Optimisations, Re-designing, Response surface method, Response surface methodology, Shape optimisation, Simulation model, Stress-life, Topology optimisation, Optimization

Citation

Kaya, N. vd. (2010). "Re-design of a failed clutch fork using topology and shape optimisation by the response surface method". Materials and Design, 31(6), 3008-3014.

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