Topology optimization: Flange yoke application

The primary purpose of this project is to implement structural topologyoptimization methods on driveshaft part called flange yoke, which maintains theconnection of a driveshaft between gearbox output and differential input flanges.The first step in this study is to determine the mechanical properties of existingflange yoke part by performing a couple of tensile tests. After identifying themechanical properties, static analysis is carried out on the existing flange yoke 3Dmodel by using FEA methods in order to determine the stress distribution and totaldisplacement. In the mean time, a similar part which is manufactured by a competitoris also modelled and analysed by FEA methods in order to compare the design withthe previous one. The next step is to create a concept model which will be used intopology optimization sequence. After creating the concept model, design variables,objective function, optimization constraints are identified and topology optimizationis perfomed by using Altair Optistruct codes on flange yoke concept model.After completing topology optimization activities, a new geometry is derivedfrom the optimized topology and FEA methods are used to perform static analysis inorder to compare the stress distribution and total displacement of the new geometrywith the existing ones.Finally, rig tests which are simulating real operating contions are used to validatethe new geometry of flange yoke which is derived from topology optimizationgeometry. As a result the new design of flange yoke is freezed and shifted to serialproduction.