@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}},
}