CAD-Based Design Optimization of Axle Housing - Ford 9-Inch Differential
Comprehensive CAD-driven, simulation-integrated design optimization process for axle housings. Demonstrates integrated parametric CAD modeling, structural simulation, and multi-objective optimization delivering lighter, stronger, and more manufacturable components.
Project Overview
This project demonstrates a comprehensive CAD-driven optimization process for Ford 9-inch differential housing as a reference model for TEXELIS. The approach integrates parametric CAD modeling with advanced simulation techniques to achieve optimal design solutions that balance performance, weight, and manufacturability.
The optimization process leverages cutting-edge design methodologies including topology optimization, parametric design variations, and multi-objective optimization algorithms. The integrated CAD-FEA workflow ensures that design modifications are automatically validated against structural and performance requirements.
Key focus areas included geometry-based optimization, performance target achievement, integrated CAD-FEA loops, and manufacturing readiness assessment. The project serves as a benchmark for similar automotive component optimization initiatives.
- Geometry-based optimization approach
- Performance targets achievement
- Integrated CAD-FEA workflow
- Manufacturing readiness assessment
Technologies & Methodologies
Advanced CAD and simulation tools combined with proven optimization methodologies
Parametric Modeling
SolidWorks/Creo parametric modeling with design automation
Simulation Integration
OptiStruct/Ansys Workbench for structural analysis
Topology Optimization
Advanced topology optimization algorithms
Design of Experiments
Statistical DOE methodology for optimization
Results & Achievements
Significant improvements in weight, performance, and manufacturability
Achieved through topology optimization
No compromise on structural integrity
Accelerated design cycles
Optimized for production
Performance Improvements
- 8-12% weight reduction achieved
- Maintained stiffness and strength requirements
- Improved stress distribution
- Enhanced fatigue life prediction
Process Benefits
- Improved manufacturing readiness
- Faster development cycles
- Automated design validation
- Reduced material costs