Optimization of Flexplate

Abstract: From 2019, all new Volvo Powertrains will be electrified, also including ICE based Powertrains. In the ICE based Powertrains with automatic transmission, a flexplate is connecting the crank shaft to the automatic transmission to transfer the power. The flexplate needs to handle torque peaks from the combustion, crank shaft whirl and axial forces generated by the torque converter. The combustion torque load is maximized at every ignition, but the load is also dependent on engine speed/load and gearbox shifts. All these loads applied to the flexplate means that the plate will be exposed to high stress levels. These high levels of stress make the flexplate more likely to break and thus, shorten its lifespan. Therefore, the objective of this thesis was to generate new optimized design proposals of the plate with minimized stress levels using the method Simulation Driven Design. Also, to understand the result, a parametrical study was performed using Design of Experiments. Using Simulation Driven Design, several concepts were generated but only two showed valid results, and they were optimized using parametrical optimization and Design of Experiments in Catia V5. Also, an attempt at a topological optimization was performed in Inspire, but the model was to complex and could not be accurately replicated in the program, making the topological optimization impossible to do. With a combination of parametrical optimization and Design of Experiments, the two concepts showed a reduced stress level of 16.4% and 11.1% compared to the original design. They also showed an increase in deformation and a slight decrease in weight. Knowing this, a conclusion could be made that Simulation Driven Design is a great method to use in product development. The results show that the combination of parametrical optimization and Design of Experiments can be used efficient during the optimization process in product development.