Engine Mount Bracket Research Articles

Applications of hydroforming processes to automobile parts

Hydroforming process recently draws attention of automotive industries due to its advantages like the increased strength, weight reduction, improved quality and reduced tooling cost. This paper summarizes some of our experiences of tube and sheet hydroforming process design by simulation technique through actual tryout. Parts included in this paper are tie bar, subframe and engine mount bracket. The simulations for the entire hydroforming processes were performed and their results were used to predict and fix the forming failures like the wrinkling and the fracture. Based on this experience, we also suggested necessary improvements in the design procedure.

Using knowledge based engineering to automate the post-processing of FEA results

An integral part of the design route for many components is the analysis of them using finite element techniques. The results of an analysis are studied and decisions made regarding the suitability of the design with respect to its engineering specification. This post-processing stage may lead to design changes that are made to address the concerns of the design team. Due to the inherent limitations in the current methods of describing and handling a complete representation of a component product model by geometrically focused CAD systems, engineers are not able to automatically integrate the FE post-processing stage into the design process. This paper describes the use of a knowledge based engineering environment to automate the post-processing phase of the analysis using an engine-mounting bracket as an example. The system developed will directly validate the initial design model by altering the product model until a satisfactory analysis result is obtained.

Optimal design of vehicle components using topology design and optimisation

An important problem in automotive industry is how to achieve better design concepts by considering structure performance and manufacturing cost in the early stages of product development. The topology design and optimisation provide an initial design concept for downstream applications, which leads to achieving better design by using computer-aided techniques. In this research, engine mount bracket design is presented to illustrate the application of topology optimisation approach for optimal design of vehicle components under dynamic loading conditions. The objective of the proposed research is to create an initial design concept, which has optimal structural layout. The effectiveness and verification of proposed approach are demonstrated with experimental results.

Prototype tryout and die design for automotive parts using welded blank hydroforming

Hydroforming is the technology that utilizes hydraulic pressure to form tube and sheet materials into desired shapes inside die cavities. It can be characterized as tube hydroforming and sheet hydroforming depending on the shape of used blank. Hydroforming offers several advantages as compared with conventional manufacturing via stamping and welding, such as part consolidation, weight reduction, improved structural strength and stiffness, lower tooling costs, fewer secondary operations, tight dimensional tolerances, low springback, and reduced scrap. In this paper, the welded blank hydroforming (WBH) technology is discussed in the aspects of formability, and the engine mount bracket and the subframe are analyzed and manufactured for the application of the technology, which have been manufactured by stamping and welding processes. Die geometry and process parameters are suggested by the computer simulation using the explicit finite element code, PAM-STAMP™. Various defects, especially wrinkling in the area of big difference of die depth and large height deviation of the die flange face, are investigated and analyzed. The numerical results are compared with prototype tryout results, and the wrinkling and the local thinning under different forming conditions are predicted.

Vibration absorbing steering device for outboard motor

A vibration absorbing steering device for an outboard motor having a swivel bracket constructed and arranged for mounting to a transom bracket of a boat and defining a vertical passageway includes a tubular pivot shaft being pivotally engaged in the passageway, an engine mount bracket designed to mount the engine for rotation with the pivot shaft, and a vibration absorbing torque tube for absorbing vibration generated by the engine. The torque tube is vertically disposed within the tubular pivot shaft and is secured at one end to the pivot shaft. A tiller arm has a pivot end attached to the upper end of the torque tube so that the tiller arm is connected to the engine mount bracket through the torque tube, and the torque tube absorbs vibration from the engine which would normally be transmitted through the tiller arm to the operator. In addition to absorbing engine vibration, the present device also permits positive steering control of the motor by manipulation of the tiller arm.

On-Board Testing and Shape Optimization of an Engine Mount Bracket

The new design for a diesel engine chassis mount bracket was fitted with strain gages and placed in a test vehicle instrumented with an on-board data acquisition system to find stress levels under actual service conditions. All experimental stresses were smaller than endurance limit of the part, so the bracket was predicted to have infinite life. In addition, the shape of the chassis mount bracket was optimized using a finite element analysis. The solution suggested removing three portions of the bracket, reducing the weight by 13.49%, and saving some manufacturing costs.

Finite Element Modeling and Design of a Diesel Engine Chassis Mount

A new diesel engine mounting bracket, that was used as a part of a repowering package for one-ton trucks, was analyzed by using a finite element model under an equivalent static loading to simulate maximum service loads. Upon finding stresses above the yield strength of the material, alterations in the design were made to stiffen the bracket in the areas of high stresses, the maximum of which was at the isolator mounting hole. This new design added several dimples and bends to increase the stiffness of the entire bracket, especially in the isolator mounting area. The results of these design changes indicated a successful reduction of the stress in that critical area. The fatigue life was evaluated for the chassis mount, and was found to be acceptable for this retrofit condition.