Light Weighting of Tractor Components Using Virtual Optimization Technique

Usually conventional iterative methods of optimization will consume more time to optimize the given design. Mostly, it becomes very difficult if multiple loads are acting on the structure contradicting each other. CAE based optimization technique becomes more useful in such cases to optimize the given design and achieve weight reduction. Optimization methods provide directions to achieve solutions faster, significantly reducing product development time. Nowadays, optimization became inevitable part among the virtual validation processes of design in industries. Various optimization methods have been successfully utilized to design the tractor components, especially mounting brackets, chassis and skid housing in the large off-road vehicle development process. Depending on the design status, different optimization approaches were followed i.e. size, topology and shape. Design freedom and available analysis time determines the type of optimization approach to be used. In case, the design is already frozen near the mass production, only minimal design change is allowed and very less time will be given to optimize the design by using size optimization. In other case, if the design is in the middle of the development stage where relatively more freedom is available to perform topology optimization which is based on the base CAD model. Optimization approach was used to reduce the weight by removing an unnecessary thickness/material while maintaining the sufficient strength. Finally, optimized design has been verified through CAE analysis. Some of the optimized components were tested and implemented successfully. 84% and 96% strain correlation were achieved in the optimized model between test and CAE. In this paper Size, Topology and Shape optimization methods are discussed and exploited to achieve an optimized design of various tractor components for different load applications and in turn to reduce the weight/cost of the components. Keywords: CAE, Size Optimization, Topology Optimization and Virtual validation