Details
| Original language | English |
|---|---|
| Pages (from-to) | 576-581 |
| Number of pages | 6 |
| Journal | Procedia CIRP |
| Volume | 119 |
| Early online date | 8 Jul 2023 |
| Publication status | Published - 2023 |
| Event | 33rd CIRP Design Conference - Sydney, Australia Duration: 17 May 2023 → 19 May 2023 |
Abstract
Designing components for thermo-mechanical loads is a challenging process. While mechanical loads like forces or pressure demand a stiff and thick-walled design, thermal loads create temperature gradients, resulting in thermo-mechanical stress from the structure's temperature proportional and, therefore, uneven expansion. In contrast to a pure mechanical load case, an initial design before optimization can already include stress levels beyond the limit of the material. Therefore, common optimization approaches for a preliminary design use exemplary systems with low-temperature gradients, so thermal stresses do not exceed the limit. From there, energy density is used to calculate the topology optimizations sensitivity and therefore decide which elements to remove and which to keep. This paper describes a novel approach for reducing thermo-mechanical stress by following the stress corresponding temperature gradients from the heat source to the sink to calculate a new sensitivity that helps to grow cooling channels. The optimization is exemplarily shown on a piston for internal combustion engines. While handling delta temperatures of 600K, results show a reduction in thermo-mechanical stress while reducing the component's mass. Because the approach reduces critical stress in a component, it allows the initial design (before the topology optimization) to have stress levels way above yield strength.
Keywords
- cooling, design, elastic, Finite Element Analysis (FEA), gradients, optimization, piston, separation, stress, structural, temperature, thermal, topology
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
Cite this
- Standard
- Harvard
- Apa
- Vancouver
- BibTeX
- RIS
In: Procedia CIRP, Vol. 119, 2023, p. 576-581.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Thermo-Elastic Topology Optimization For High Temperatures Gradients Using Load Separation
AU - Bode, Behrend
AU - Herrmann, Kevin
AU - Reusch, Jannis
AU - Plappert, Stefan
AU - Ehlers, Tobias
AU - Gembarski, Paul Christoph
AU - Hasse, Christian
AU - Lachmayer, Roland
N1 - Funding Information: This report is the scientific result of a research project undertaken by the FVV eV and performed by the institut of product development (IPeG) at the Leibniz University Hannover under the direction of Prof. Dr.-Ing. Roland Lachmayer and the Institut for Simulation of reactive Thermo-Fluid Systems (STFS) at the Technical University Darmstadt under the direction of Prof. Dr.-Ing. Christian Hasse. The FVV would like to thank Prof. Lachmayer Prof. Hasse and their scientific research assistant - M.Sc. Behrend Bode and M.Sc. Jannis Reusch for the implementation of the project. We gratefully acknowledge the support received from the project coordination and from all members of the project user committee. The project was self-financed (funding no. 1367) by the FVV eV.
PY - 2023
Y1 - 2023
N2 - Designing components for thermo-mechanical loads is a challenging process. While mechanical loads like forces or pressure demand a stiff and thick-walled design, thermal loads create temperature gradients, resulting in thermo-mechanical stress from the structure's temperature proportional and, therefore, uneven expansion. In contrast to a pure mechanical load case, an initial design before optimization can already include stress levels beyond the limit of the material. Therefore, common optimization approaches for a preliminary design use exemplary systems with low-temperature gradients, so thermal stresses do not exceed the limit. From there, energy density is used to calculate the topology optimizations sensitivity and therefore decide which elements to remove and which to keep. This paper describes a novel approach for reducing thermo-mechanical stress by following the stress corresponding temperature gradients from the heat source to the sink to calculate a new sensitivity that helps to grow cooling channels. The optimization is exemplarily shown on a piston for internal combustion engines. While handling delta temperatures of 600K, results show a reduction in thermo-mechanical stress while reducing the component's mass. Because the approach reduces critical stress in a component, it allows the initial design (before the topology optimization) to have stress levels way above yield strength.
AB - Designing components for thermo-mechanical loads is a challenging process. While mechanical loads like forces or pressure demand a stiff and thick-walled design, thermal loads create temperature gradients, resulting in thermo-mechanical stress from the structure's temperature proportional and, therefore, uneven expansion. In contrast to a pure mechanical load case, an initial design before optimization can already include stress levels beyond the limit of the material. Therefore, common optimization approaches for a preliminary design use exemplary systems with low-temperature gradients, so thermal stresses do not exceed the limit. From there, energy density is used to calculate the topology optimizations sensitivity and therefore decide which elements to remove and which to keep. This paper describes a novel approach for reducing thermo-mechanical stress by following the stress corresponding temperature gradients from the heat source to the sink to calculate a new sensitivity that helps to grow cooling channels. The optimization is exemplarily shown on a piston for internal combustion engines. While handling delta temperatures of 600K, results show a reduction in thermo-mechanical stress while reducing the component's mass. Because the approach reduces critical stress in a component, it allows the initial design (before the topology optimization) to have stress levels way above yield strength.
KW - cooling
KW - design
KW - elastic
KW - Finite Element Analysis (FEA)
KW - gradients
KW - optimization
KW - piston
KW - separation
KW - stress
KW - structural
KW - temperature
KW - thermal
KW - topology
UR - http://www.scopus.com/inward/record.url?scp=85169886678&partnerID=8YFLogxK
U2 - 10.1016/j.procir.2023.03.113
DO - 10.1016/j.procir.2023.03.113
M3 - Conference article
AN - SCOPUS:85169886678
VL - 119
SP - 576
EP - 581
JO - Procedia CIRP
JF - Procedia CIRP
SN - 2212-8271
T2 - 33rd CIRP Design Conference
Y2 - 17 May 2023 through 19 May 2023
ER -