Topology Optimization Study of Coupling Housing

Sammanfattning

This thesis investigates the potential of topology optimization to reduce the weight of an all-wheel-drive (AWD) coupling housing while maintaining structural integrity and manufacturability. The study was conducted in collaboration with BorgWarner Sweden AB and applied finite element analysis (FEA) and topology optimization using ANSYS Workbench. The project followed an adapted Double Diamond framework to structure the process, focusing on simulation and optimization phases rather than concept generation. The optimization focused on the rib geometry of the housing, which accounts for 6.6% of the total weight, under the constraint that all functional and assembly surfaces remain unchanged. Manufacturing limitations for casting were integrated into the optimization process to ensure manufacturability. The redesigned housing achieved a total weight reduction of 4.8%, with a significant 72.4% reduction in rib weight, while structural validation confirmed that stress levels remained below those of the original design. The results demonstrate that topology optimization is an effective tool for weight reduction in automotive components when combined with manufacturing constraints and performance requirements. Future work should explore optimization beyond the ribs and incorporate environmental assessments such as Life Cycle Analysis to align with sustainability goals.