Design optimization and finite element analysis of alternator casted housing. (2021)

• Record Type: Journal Article
• Authors: Sangeetha, M.; Anderson, A.; Ajith, N.; Raphael, S.I. Meshack; Prithivi, P.B.
• Is Part Of: Materials today. Volume 45:Part 7(2021)
• Page Start: 5911
• Page End: 5915
• Publication Date: 2021
• Subjects: Alternator -- Design optimization -- Casted housing -- Aluminum alloy -- Magnesium alloy; Materials science -- Congresses -- Periodicals; 620.1
• DOI: 10.1016/j.matpr.2020.08.772
• Languages: English
• ISSNs: 2214-7853

Abstract

Highlights: The modelling and stress analysis were carried out for the Aluminium alloy housing. The material was changed as Magnesium Alloy and carried out the analysis. The material weight of the housing is reduced by 5.76% for Magnesium Alloy housing. The ventilation area is increased by 25.8% by reduction in stress values for optimised model. Abstract: The paper focuses on following the Design Optimization techniques that can be used by the designer to develop the robust design on the given product.This Robust design will help in reducing the Manufacturing cost, gives better performance, maximum durability, less failure and maximum profit. The optimum design can be achieved by doing Iterations on the design and analyzing its results.This paper deals with designing the Alternator housing which is available in the market and to implement design optimization on the existing housing to reduce the weight of the product and to increase the functional requirement of the product such as increasing the ventilation area of the housing for achieving better cooling, Also to increase the manufacturing feasibility we incorporate uniform thickness in the housing for reducing the risk of casting defects such as shrinkage, voids, sink marks, etc., a comparison study is done on the optimized housing with two materials Aluminum alloy Alsi9cu3 and Magnesium Alloy AZ91D and the final conclusion is given based on the Finite element analysis results. Computer aided design of alternator assembly and Finite element analysis is carried out using CATIA V5 software.