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Topology Optimization Study of Coupling Housing

Lundberg, Alice LU (2026) MMKM05 20252
Innovation
Abstract
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... (More)
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. (Less)
Popular Abstract (Swedish)
Denna examensrapport undersöker potentialen hos topologioptimering för att
minska vikten på ett all wheel drive (AWD) kopplingshus samtidigt som den
strukturella integriteten och tillverkningsbarheten bibehålls. Studien genomfördes i
samarbete med BorgWarner Sweden AB och använde finita elementanalys (FEA)
och topologioptimering i ANSYS Workbench. Projektet följde en anpassad Double
Diamond metod för att strukturera processen, med fokus på simulerings- och
optimeringsfaser snarare än konceptgenerering.
Optimeringen fokuserades på ribbgeometrin i huset, som står för 6,6 % av den totala
vikten, under begränsningen att alla funktionella ytor och monteringsytor förblir
oförändrade. Tillverkningsbegränsningar för gjutning integrerades... (More)
Denna examensrapport undersöker potentialen hos topologioptimering för att
minska vikten på ett all wheel drive (AWD) kopplingshus samtidigt som den
strukturella integriteten och tillverkningsbarheten bibehålls. Studien genomfördes i
samarbete med BorgWarner Sweden AB och använde finita elementanalys (FEA)
och topologioptimering i ANSYS Workbench. Projektet följde en anpassad Double
Diamond metod för att strukturera processen, med fokus på simulerings- och
optimeringsfaser snarare än konceptgenerering.
Optimeringen fokuserades på ribbgeometrin i huset, som står för 6,6 % av den totala
vikten, under begränsningen att alla funktionella ytor och monteringsytor förblir
oförändrade. Tillverkningsbegränsningar för gjutning integrerades i
optimeringsprocessen för att säkerställa tillverkingsbarhet. Det omdesignade huset
uppnådde en total viktminskning på 4,8 %, med en betydande minskning av ribbvikt
på 72,4 %, medan strukturell validering bekräftade att spänningsnivåerna förblev
lägre än i originaldesignen.
Resultaten visar att topologioptimering är ett effektivt verktyg för viktminskning av
fordonskomponenter när det kombineras med tillverkningsbegränsningar och
prestandakrav. Framtida arbete bör undersöka optimering utöver ribborna och
inkludera miljöbedömningar såsom livscykelanalys (LCA) för att uppnå
hållbarhetsmål. (Less)
Please use this url to cite or link to this publication:
author
Lundberg, Alice LU
supervisor
organization
course
MMKM05 20252
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Topology Optimization, Finite Element Analysis (FEA), Weight Reduction, Double Diamond Method, Product Development Methodology
language
English
id
9232203
date added to LUP
2026-06-10 10:53:59
date last changed
2026-06-10 10:53:59
@misc{9232203,
  abstract     = {{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.}},
  author       = {{Lundberg, Alice}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Topology Optimization Study of Coupling Housing}},
  year         = {{2026}},
}