C2R-UsingAnalysistoInnovatewithNewMaterials.pdf - Design...

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8 | CONCEPT TO REALITY | FALL 2013/WINTER 2014 Design Strategies T The Korean-Chinese Suzhou Samsung Electronics Co. joint ven- ture develops and produces major home appliances, including refrigerators and washing machines. The company con- stantly seeks ways to lead the competition by reducing the volume of material in its products without sacrificing top-rate performance. The household appliances sector is an exceptionally competitive arena, so appli- ance manufacturers across the globe place particular emphasis on technical innova- tion and cost effectiveness when creating designs. While streamlining products and controlling the production process are important factors in cost control, the selection of materials also plays a major role in keeping production costs down. Simulation plays a key role in achieving these objectives at Samsung as it explores lightweighting opportunities and alterna- tive material choices for its commercial product line. Lightweighting Leads to Optimized Belt Pulley Cheng Fuping, Suzhou Samsung man- ager, explains that the company optimized the design of a belt pulley for one of its washing machines. The belt pulley con- nects the motor to the drum and drives the drum during operation. Conventionally, the belt pulley is con- structed from cast aluminum. With cost pressures increasing, Suzhou Samsung was interested in reducing the pulley’s weight by optimizing its design and/or using new materials for its production. When considering alterna- tive materials, both their performance and cost become pri- mary factors – so Suzhou Samsung employs topology optimization to meet the chal- lenges relating to design and materials. To carry out optimization on the pulley, Suzhou Samsung chose OptiStruct®, a structural analysis and optimization solver and a key component of Altair’s HyperWorks® suite of computer-aided engineering (CAE) tools. “OptiStruct provided us with important optimization capabilities,” says Cheng, “such as topology, size and shape optimization. We were particularly interested in topology optimization to obtain the most efficient structure or distribution of material used in the structure.” Analysis and optimization tools enable Samsung engineers to reduce the cost of appliances without sacrificing performance. Using Analysis to Innovate with New Materials CAD model of optimized four-spoke aluminum-based belt pulley Topology optimization results from Altair OptiStruct Original five-spoke aluminum belt pulley design By Beverly A. Beckert The optimized four-spoke aluminum belt pulley is now in mass production
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FALL 2013/WINTER 2014 | CONCEPT TO REALITY | 9 The aluminum pulley that Suzhou Samsung wanted to optimize incorporated five spokes. Engineers sought to find the optimal material distribution or the minimum volume for the spokes area of the pulley.
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