Robust Design Crankshaft Optimization

A multi-disciplinary real application case

Model definition and parameterisation

Rup

Bezup

Rmid Rdown Bezdown

Engine crankshaft, dynamically coupled with 5 radial bearings and 1 axial bearing The geometry of the crankshaft (web shape) is defined and parameterised by ProEngineer 10 geometric variables, that are assigned to the web side (Bezier curves) and to fillet radius

Modal Analysis by ANSYS Workbench

The first natural frequency is computed by ANSYS Workbench (~150 Hz with freefree BC)

Equivalent discretized model by AVL Autoshaft

AVL-Autoshaft

AVL-Excite

The crankshaft is discretized by finite volumes: the equivalent model of mass point is computed AVL-Excite uses this model to calculate the forces (inertial, active and reactive) acting on the crankshaft and in particular in correspondence of the bearings

Dynamical coupling with bearings by AVLExcite

The equivalent model of crankshaft is coupled with the bearings The general data (bearing type, friction coefficients, oil pressure and viscosity, roughness and clearance, etc.) are specified

Hydrodynamic analysis of bearings by AVL Excite

The fitness of the bearings is quantified by the evaluation of three functions, calculated by a notstationary hydrodynamic analysis of the bearings in a complete cycle The complete cycle analysis is required since the contact point (and thus risk of damage) in the bearing is not fixed during a cycle

Definition of stochastic variables and optimisation objectives

Oil film pressure is considered as deterministic variable [110bar] 10 geometric deterministic variables (web shape) Bearing clearance and roughness are stochastic variables (due to manifacturing tolerances): defined by a fixed mean value and a standard deviation

Definition of optimisation objectives (deterministic and stochastic)

Obj.1: minimize crankshaft mass (DETERMINISTIC) Obj.2: maximize first natural mode frequency (DETERMINISTIC) Obj.3: minimize mean of maximum oil film pressure (STOCHASTIC) Obj.4 minimize mean of oil film power loss (STOCHASTIC) Obj.5 maximize mean of oil film thickness (STOCHASTIC) Constr. on standard deviation of oil film pressure, loss and thickness to be lower than original (STOCHASTIC)

modeFRONTIER workflow setup

Design parameters Input variables 10 geometric var for crankshaft, oil pressure, 10 stochastic var for bearings Output variables Mass, frequency, oil film power loss, pressure and thickness

Design goals Minimize mass, mean of power loss and pressure Maximize frequency and mean of thickness Optimizations set-up data Sampling phase: Original configuration nr initial individuals: 1 Exploration phase: MOGT scheduler 6 Simplex iterations for 4 players steps

Constraints Standard deviation of oil film output variables less than original

modeFRONTIER post-processing

The numbers indicate Pareto front designs Color=Power loss

Diameter= Max pressure

46 designs of the total 180 computed by MOGT belong to Pareto front (not-dominated)

modeFRONTIER post-processing

Pareto front designs are compared relatively to the 5 objectives Original and best design 156 (arbirary chosen) are indicated in green

modeFRONTIER post-processing

original

best

objective

constraint
Mean film Mean loss pressure [bar] film thickness [mm]

Mass [mm3] original best

3.77 106 3.54 106

Frequency

[Hz]

Mean pressure [bar]

thickness [mm]
1.174E-5 1.175E-5

[W]

loss [W]

150 164

79.3 77.0

628 612

6.77 6.77

1.48E-7 1.48E-7

64.3 64.3

modeFRONTIER post-processing

original

best

Comparison between original and optimized oil film pressure

modeFRONTIER post-processing
Values of clearance for 3 bearings vs power loss: only one bearing indicates a inverse linearity

The distribution of clearance values is normal such as defined

modeFRONTIER post-processing

Similar conclusions for roughness vs power loss

Conclusion

The basic definition of Robust Design has been formulated

The necessity of Robust Design has been clarified by two examples in different fields

The application of Multi Objective Game Theory algorithm has revealed particularly efficient for the solution of these kind of applications