Target of the project
Weight reduction because of
- CO2 reduction
- car weighttargetgoals
- cost reduction
Result of the project
- Weight reduction 25%(original weight 12.5 kg)
- Amortization of all costs within 1 year
- Saving potentials per year 2 Mio €
Example: Maximum material removement
|
Standard design
|
hofer weight-optimised solution |
 |
 |
- Weight reduction up to 15%
- Cost reduction 15%
Example: Optimization of gearbox housing
FEM calculation for:
- Realization of a homogeneous stress distribution
- Durability estimations
- Evaluation of acoustical behavior
| |
Problem analysis |
hofer solution |
 |
 |
 |
|
Failure because of
inhomogeneous stress
distribution
|
Problem analysis through
simulation of the failure
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Systematic solution approach
through FEM and expert analysis
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Example: Aluminum versus Magnesium optimized housing
| Aluminium design |
Magnesium design |
 |
 |
- Equal stiffness and strength
- 35% less weight
- Equal manufacturing costs
Example: Rib optimization
| Problem analysis |
hofer solution |
 |
 |
Reference project (gearbox housing):
Target:
- achieve same strength and stiffness
- achieve same acoustic behaviour
- use identical machines and assembly line
- weight reduction
Solution:
- Component with 18 % less weight, 18 % less costs, same geometrical properties
Method:
- FEM Simulation
- complete redesign
- casting simulation
