Topology Optimization using

ANSYS R18
at ZF DO BRASIL
Author: Janaina Rodrigues
Co-author: Sergio Scabar
PRESENTATION TOPICS

ZF Group overview

Problem description

Methodology

Goals

Conclusion and next steps

ZF Group - 2016
ZF Group Industrial Division
Problem description

Tractor front Axle

Front bracket
Problem Description

The geometry was developed through a process of trial and

error

Is there another optimal geometry?

The mass could be reduced?

What is the relation between mass reduction and stiffness

structural?
Methodology Mesh
Methodology Constraint

Fixed Support
Methodology Loads
Methodology Boundary conditions

Bonded

Bonded
Current design results - Deformation

all contacts was considered bonded

Current design results - Deformation
Goals Topology Optimization

Use ANSYS Workbench version 18 to

find an optimal geometry with a relation
between the stiffness and mass
reduction
Design space

Use a gross geometry to

evaluate the application
necessity

Keep the same interface

geometry
Design space Deformation

all contacts was considered bonded

Methodology Objective / Constraint
Solution Solver Output
Design Space Pseudo Density Elements
Export to .STL
Create the optimized geometry
New design Deformation
Current design Maximum Principal Stress

136
New design Maximum Principal Stress

152

+12%
Other Load Cases
LOAD CASE 1

LOAD CASE 3

LOAD CASE 2
Design cycle

With optimization tool

Project
Without optimization tool

Project
Design space
Design
parts
FEA +
Optimization
FEA

Design parts
no Is it
approved
?
FEA
yes

Validation
Validation
Conclusion

-22%

1,35.106 mm3 7,56.106 mm3 1,04.106 mm3

Next steps

Check the stress level considering all the real boundary conditions.