Engine Mount Bracket Research Articles

Failure analysis-based mass reduction of an aluminium alloy engine mounting bracket using Design of Experiments approach

In this study, mass reduction of an engine mounting bracket has been performed without changing the failure mode. Firstly, failure modes were determined experimentally using failure loads provided by the vehicle manufacturer. Then critical stress concentration areas and suitable mass reduction regions were determined by using Finite Element Analysis (FEA) for these load cases. A structural optimisation process was carried out using Design of Experiment-Response Surface Methodology (DOE-RSM) to minimise the mass while keeping the failure load as constant as possible. When the stress values obtained from the preliminary structure are compared with the values obtained from the optimised part, it was seen that this target has been mostly achieved. A total mass reduction of 4.31 % was achieved in the new part through failure mode analysis. Furthermore, it was found that a financial saving of 129,000 Euro could also be achieved.

Weight Optimization of Engine Mounting Bracket for Commercial Vehicle by Using FEA Packages

Right now, car part planning is totally grounded on strength and lightweight according to as portability is worried for execution improvement. Thus, for saving of cost in item styles of the hall of the machine and with thought of the heaviness of passage in which a district can be concentrated having lower stresses will be cut inside figure of the hallway. The fundamental motivation behind a machine mounting type is to help the power - train framework in a machine in all states of street shells including for sure, lopsided street shells. It's authentically sensitive to change the supporting areas and the kinds of help after the machine is raised, the mounting classes should be justified in the plan stage. This plan contains the investigation of streamlining of a machine mounting type and correlation among being and upgraded machine mounting type. Improve model will fabricate utilizing aluminum material with the supporting of glass fiber subcaste. Computer aided design model has been created through back designing. The sort of Mahindra Scorpio Motor is to be taken for study. Subsequent to examining the machine mounting sort of 4-wheeler, Improvement is finished. Trial testing will perform with assistance of UTM and strain check. Key Words: CAD/CAM, Ansys, Engine Mounting Bracket

Towards an Optimal Motor Mounting Bracket Using Topology Optimization Combined with Sustainability and Manufacturing Cost Analysis

The engine is the most important component of a vehicle. It attaches to the main frame via the engine mounting bracket which supports weight and operating loads. The engine mount therefore plays a crucial role in the durability and comfort of the vehicle. This article contributes to the search for the most optimal model from the point of view of resistance, environmental impact, and manufacturing cost. This involves, on the one hand, optimizing the support by reducing its initial mass by 30%, and on the other hand, seeking suitable material and manufacturing process with the least environmental impact. To this end, topology optimization will be combined with an environmental assessment and a manufacturing cost analysis. Four materials will be tested and evaluated. Finally, a cost analysis will present a comparison between a conventional process and 3D printing.

Vibration Analysis of Engine Mounting Bracket of a Car using Experimental and FEA

Abstract: Overall, the research presented in this dissertation focused on the optimization of the tie rod of a steering system of a car using experimental and FEA analysis. The tie rod was traditionally made of cast iron, but in this study, an aluminum material was used. The results of the theoretical, experimental, and FEA analysis were compared to the conventionally used tie rod material in terms of cost and weight optimization. The study found that the use of aluminum material for the tie rod resulted in a reduction in weight and cost without compromising on the functional strength of the tie rod. Additionally, the research also discussed the importance of regular maintenance and inspection of the steering system and suspension, as well as the potential failure modes of the tie rod and their causes.

Topology optimization of engine mounting bracket

Topology optimization is an effective approach for optimizing the layout of the component under operating constraints without losing its functionality. Density based approach is usually employed for solving material distribution problems resulting in minimization of structural compliance. Finite element method is proven to be the best tool for analyzing components under various circumstances. The need of this research is to explore the process of material removal in density based topology optimization which is exemplified by analysing an engineering component. In this work, Engine mounting bracket is chosen for optimization as it mounts the engine with the chassis. Design enhancement is subjected to 5% and 10% mass reduction percentages. Static structural analysis was performed and the results were compared for the basic and optimized design models. As a result, 9.97% mass reduction, a change of 27.9 MPa in maximum stress and change of 0.04526 mm in deformation were achieved.

Modeling and Weight Optimization of Engine Mounting Bracket

Engine mounts themselves are small parts that are meant to stabilize, as well as properly align, a vehicle’s engine. So, even though these mounts are small, they play a large role in the overall functionality of the heart of your vehicle. Moreover, when these supposedly small and minor aspects of the vehicle go bad. An automotive engine-body chassis system is typically subjected to unbalanced engine forces, uneven firing forces especially at the idling speeds, shaking forces and torques due to reciprocating parts, dynamic excitations from gearboxes and accessories, and road excitation. These tendencies give rise to undesired vibrations which lead to an uncomfortable ride and also cause additional stresses in the automobile frame and body. Brackets plays a vital role when the vibrations are produced it helps engine to maintain a static hold so their far no failure should occur and also while accidents take place it protects them from major damage..

Topology Optimization of an Engine Mounting Bracket

Engine mounting system is an essential component to a vehicle in providing the isolation of vibration and noise which are generated by the engine. While various system designs have been studied for improvements, less attention were given to study the effects of vibrational load to subcomponents of the mounting system – for example: the engine bracket. At high frequency working condition, the engine bracket may experience fatigue failure due to cumulative vibrational loading. Henceforth, any efforts to further reduce the structural weight of the said brackets may degrade its strength and this may lead to catastrophic result. This study aimed to enhance the mechanical property of an engine-mounting bracket with respect to cyclic load by means of weight-reduction topology optimization. An actual enginemounting bracket under vibrational load transmitted was modeled and analyzed using two different computer aided design software. An improved design of engine mounting bracket was modeled by reducing its total weight via the use of HyperWorks. In conclusion, this study has discovered an incremental of stress concentration area across the bracket when predetermined load is applied to the weight-reduced engine bracket.

Failure analysis of engine mounting bracket of a passenger car

This paper presents the failure analysis of an engine mounting bracket. During the proving ground testing, the right brackets of the three testing cars get broken or cracked at the mileage about 7,000 km. In order to determine the causes of the failure, a nonlinear finite element method (FEM) and failure morphology analysis together with mechanical properties, chemical components and micro-structural analyses of the specimen s material have been performed. The metallographic observation shows the precipitates observed at the inner and outer surfaces, which reduces the strength of inter-granular and then causes the fatigue fracture initiation at the inter-granular. The FEM results show that, the max mises stress is right just at the fillet of bracket, where is the initiation of the crack, and it is a little higher than the yield stress of SAPH400. An optimized structure is proposed, the max tress reduces 20%, and the following tests show the optimized bracket achieving the test mileage more than18,000 km and meets the test requirement.

Improvement of Fatigue Life and Dynamic Strength of an Engine Mounting Bracket Using Experimental and Numerical Approaches

Improvement of Fatigue Life and Dynamic Strength of an Engine Mounting Bracket Using Experimental and Numerical Approaches

Shape Optimum Design by Basis Vector Method Considering Partial Shape Dependence

Regarding the case of complicated structural shape optimization, there are cases where there are partial shapes such as holes and irregularities inside the structure. Concerning the complex structural optimization shape, the relationship between the external boundary shape and the internal local shape should be maintained, and how to change the internal partial shape while maintaining a subordinate relationship with the external form has become an important issue. Currently, there is no good solution to this kind of problem using general optimization design software. Therefore, this paper proposes to use the basic vector method to solve the local shape dependency problem of partial shapes. First, this paper classifies the subordinate problems of partial shape into three primary patterns, theoretically proving a method for controlling subordinate relationships of partial forms, respectively. Then, the research also provides two classical application examples: shape optimization of a steam turbine implantation section and stress distribution optimization of an engine mount bracket. The results show that the optimization method is effective for the partial shape subordination problem in complex structural shape optimization problems. Finally, the study examines the problem of making a vectorial vector, a correlation between the basis vector and the remeshing problem of the analysis model in shape optimization, and further substantiates the validity of the method proposed by the body using the analysis result of the actual structural shape optimization case.

Design, Analysis and Optimization of Engine Mounting Bracket for SAE Supra Car Using Finite Element Analysis

<div class="section abstract"><div class="htmlview paragraph">The power train components of vehicles are firmly attached to the Engine mounting bracket. It plays very important role in performance of vehicle and its comfortable ride. As SAE India Supra car was high performance vehicle, the mounting brackets undergo high static and dynamic loading conditions due to that Huge amount of vibrations were produced. By careful designing and analysis of engine mounting bracket we can mitigate the vibration produced in the vehicle. The current paper discusses the modelling of bracket in Catia, Static and Modal Analysis of bracket was carried out in FEAST Software. Optimization of bracket is carried out in hyper mesh Software for weight reduction. A Formula Student car is required to be highly manoeuvrable and quick with high rates of acceleration and deceleration. Hence the mounting of the engine should be well constrained and the mount brackets need to be light-weight and designed to safely bear the inertial loads and maximize vibration transmission. FEA has been done to check the frequency and loading response of the brackets before finalizing the design. The design of the brackets has been experimentally validated after the actual implementation and testing of the vehicle. Finally, the comparison of results (Displacement, von-mises stresses and strain) for Mild Steel, Aluminium 6063, Carbon Fiber Composite and Glass Fiber Composite is discussed.</div></div>

Engine-bracket drilling fixture layout optimization for minimizing the workpiece deformation

Purpose Fixture layout design is concerned with immobilization of the workpiece (engine mount bracket) during machining such that the workpiece elastic deformation is reduced. The fixture holds the workpiece through the positioning of fixturing elements that causes the workpiece elastic deformation, in turn, leads to the form and dimensional errors and increased machining cost. The fixture layout has the major impact on the machining accuracy and is the function of the fixturing position. The position of the fixturing elements, key aspects, needed to be optimized to reduce the workpiece elastic deformation. The purpose of this study is to evaluate the optimized fixture layout for the machining of the engine mount bracket. Design Methodology Approach In this research work, using the finite element method (FEM), a model is developed in the MATLAB for the fixture-workpiece system so that the workpiece elastic deformation is determined. The artificial neural network (ANN) is used to develop an empirical model. The results of deformation obtained for different fixture layouts from FEM are used to train the ANN and finally the empirical model is developed. The model capable of predicting the deformation is embedded to the evolutionary optimization techniques, capable of finding local and global optima, to optimize the fixture layouts and to find the robust one. Findings For efficient optimization of the fixture layout parameters to obtain the least possible deformation, ant colony algorithm (ACA) and artificial bee colony algorithm (ABCA) are used and the results of deformation obtained from both the optimization techniques are compared for the best results. Research Limitations Implications A MATLAB-based FEM technique is able to provide solutions when the repeated modeling and simulations required i.e. modeling of fixture layouts (500 layouts) for every variation in the parameters requires individual modeling and simulation for the output requirement in any FEM-based software’s (ANSYS, ABACUS). This difficulty is reduced in this research. So that the MATLAB-based FEM modeling, simulation and optimization is carried out to determine the solutions for the optimized fixture layout to reach least deformation. Practical Implications Many a time the practicability of the machining/mechanical operations are difficult to perform costly and time-consuming when more number of experimentations are required. To sort out the difficulties the computer-based automated solution techniques are highly required. Such kind of research over this study is presented for the readers. Originality Value A MATLAB-based FEM modeling and simulation technique is used to obtain the fixture layout optimization. ANN-based empirical model is developed for the fixture layout deformation that creates a hypothesis for the fixture layout system. ACA and ABCA are used for optimizing the fixture layout parameters and are compared for the best algorithm suited for the fixture layout system.

Review on Analysis of Engine Mounting Bracket

Engine mounting bracket plays an important role in reducing vibration as well as noise. It is one of the main component of engine mounting assembly. The purpose of an engine mounting bracket is to support the power train system and to properly balance the engine. This paper includes the study of FEA analysis and optimization of existing engine mounting bracket. The CAD model is designed on basis of previous used bracket and Analysis is done in ANSYS Software. After analyzing it, the portion of bracket which gets failure is redesign and analyze again so that the modified bracket will sustain at new loading condition.

Optimization Methodology for Continuous Heterogeneous Structures: A Preliminary Design of an Engine Mounting Bracket

A numerical methodology is presented which is based on Topology Optimization (TO) approach for designing continuous heterogeneous structures. This method is then exploited to reduce weight and to increase stiffness in mechanical components. Useful guidelines for the evaluation of equivalent material properties of metallic cellular structures are discussed, and they are applied for the optimization process of an engine mounting bracket under realistic loading and boundary conditions. The outcome of TO, which is related to the material density distribution into the design space, is critically reviewed for the definition of bulk, lattice and void regions within the component.

Stress analysis of engine mounting assembly of a three wheeler

One of the essential parts of an auto vehicle is an engine mounting bracket, which helps in mounting the engine on the chassis. This paper analyses and compares the existing bracket design of one of the famous three-wheeler of Scooter India limited named as Vikram 750 D with five new alternative models using finite element analysis. In the first part, linear structural finite element analysis of engine mounting bracket of the existing design was carried out to determine the maximum stresses and deformations in the existing model and then identical analysis was conducted for five proposed models of the mounting brackets. The maximum stresses and deformations of the proposed models were compared with that of the existing model to identify a better design. The weight of the existing model and five proposed model were also compared to obtain an optimal design.

Design of Engine Mount Bracket for a FSAE Car for Deferent Loading Condition

Engine mounts have an important function of containing firmly the power-train components of a vehicle. Correct geometry and positioning of the mount brackets on the chassis ensures a good ride quality and performance. As an FSAE car intends to be a high performance vehicle, the brackets on the frame that support the engine undergo high static and dynamic stresses as well as huge amount of vibrations. Hence, dissipating the vibrational energy and keeping the stresses under a pre-determined level of safety should be achieved by careful designing and analysis of the mount brackets. Keeping this in mind the current paper discusses the modeling, Finite Element Analysis, Modal analysis and mass optimization of engine mount brackets for a FSAE car. As the brackets tend to undergo continuous vibrations and varying stresses, the fatigue strength and durability calculations also have been done to ensure engine safety. Keywords: FEA; Modal Analysis; Static Analysis; Optimization; Mounting Bracket

Design and Analysis of Engine Mount Bracket for Go-Kart

This paper deals with Finite Element Analysis (FEA) of engine mount bracket is carried out to check its natural frequency, maximum equivalent stress analysis and deformation. The most vibrations of go-kart’s engine are taken by the engine bracket however it may get failed due to various forces. The engine load is also considered during the static condition of bracket design. Vibrations and loading of engine bracket has been continuously a concern which may lead to structural failure if the resulting vibration and stresses are severe and excessive. It is a significant study which requires in-depth investigation to understand the structural characteristics and its dynamic behavior. Main focuses on Design and FEA of an engine bracket specifically for a go-kart in which structural analysis will be carried out and for natural frequencies through modal analysis will be determined by changing material properties and material for weight optimization.

Strength Performance Analysis and Improvement of Engine Mounting Bracket for a Commercial Vehicle

With the rapid development of the automotive industry and the increasing demand of consumers for the quality of automotive products, improving the reliability of automotive products has become the "top priority" of enterprises. While improving the reliability level of engine mounting bracket for commercial vehicles, it can not reduce the mechanical strength performance of the structure. Therefore, it is of practical significance to optimize the structure and study the reliability of the mounting bracket. The engine mounting bracket mainly supports the weight of the engine. According to the design space and process requirements, the topology optimization design is carried out to find the most reasonable material distribution. Structural optimization of mounting bracket can be demonstrated by different schemes in conceptual design stage, and verified by finite element analysis and strength test. Among many complex factors affecting structural reliability, product design is the most fundamental one. The design determines the reliability of engine mounting bracket, and the defects left in the design can not be completely solved in production and use. During the design and development of a commercial vehicle, the engine mounting bracket broke during road test. Through macro-analysis of the fracture site, it is preliminarily determined that the suspension bracket system suffers from rapid fracture due to excessive load under driving conditions, resulting in stress concentration. The finite element model of powertrain mounting bracket is established, the strength of mounting bracket is analyzed, and the structure of engine bracket is improved according to its stress distribution and processing requirements. Comparing the performance of engine mounting bracket before and after improvement, it shows that the strength of engine mounting bracket has been improved obviously, and the weight has been reduced effectively. It provides an important reference for the strength performance design of engine mounting bracket.

Shell Analysis and Optimisation of a Pure Electric Vehicle Power Train Based on Multiple Software

Motor end cover mounting fracture is a problem recently encountered by novel pure electric vehicles. Regarding the study of the traditional vehicle engine mount bracket and on the basis of the methods of design and optimisation available, we have analysed and optimised the pure electric vehicle end cover mount system. Multi-body dynamic software and finite element software have been combined. First, we highlight the motor end cover mount bracket fracture engineering problems, analyse the factors that may produce fracture, and propose solutions. By using CATIA software to establish a 3D model of the power train mount system, we imported it into ADAMS multi-body dynamic software, conducted 26 condition analysis, obtained five ultimate load conditions, and laid the foundations for subsequent analysis. Next, a mount and shell system was established by the ANSYS finite element method, and modal, strength, and fatigue analyses were performed on the end cover mount. We found that the reason for fracture lies in the intensity of the end cover mount joint, which leads to the safety factor too small and the fatigue life not being up to standard. The main goal was to increase the strength of the cover mount junction, stiffness, safety coefficient, and fatigue life. With this aim, a topology optimisation was conducted to improve the motor end cover. A 3D prototype was designed accordingly. Finally, stiffness, strength, modal, and fatigue were simulated. Our simulation results were as follows. The motor end cover suspension stiffness increases by 20%, the modal frequency increases by 2.3%, the quality increases by 3%, the biggest deformation decreases by 52%, the maximum stress decreases by 28%, the minimum safety factor increases by 40%, and life expectancy increases 50-fold. The results from sample and vehicle tests highlight that the component fracture problem has been successfully solved and the fatigue life dramatically improved.

Analysis of engine mounting bracket for an automobile using FEA

Objectives: The study is conducted to perform the modelling and structural analysis of engine mounting bracket and also examine the vibration isolation using FFT analyzer. Methods/ Statistical analysis: Modelling and analysis of the engine mounting bracket is carried out using solid works software. Static and modal analysis are performed to check the stress, deflection and effect of natural frequencies under loading conditions. The experimentation is also performed using FFT analyzer to check the effect of vibrations on the bracket in horizontal and vertical position. Findings: Analysis was carried out for different materials like natural rubber, neoprene, and silicon rubber. On comparing the results, the silicon rubber found better material as compare to other materials due to its low stress and deflection value and better frequency values. The experiment results shown that in the horizontal position the vibration were less than the vertical position. Application/ Improvements: Silicon rubber is considered better material for engine mounting bracket for vibration damping. This approach also helps us to find out the weak area in early design phase. Keywords: Engine Mounting Bracket, FFT Analyser, Static and Modal Analysis, Solid Works, FEA