ALTERNATIVE MATERIAL SELECTION AND TOPOLOGY OPTIMIZATION FOR COMPONENTS OF STONERIDGE'S SMARTBAR ACTUATOR

Abstract

The goals of this project are to reduce the cost and weight of the SmartBar actuator that is produced by Stoneridge, Inc. The team accomplished these by changing the materials of three parts, the magnet holder, planet carrier, and ring gear, as well as conducting topology optimization on them. The stakeholder requirements are ensuring a minimum lifetime, remaining within the packaging envelope, being capable of tight manufacturing tolerances, and reducing cost and weight. To verify that these were met, the team conducted several Ansys analyses to produce data for lifetime parameters, shock and vibration load case tests, linear fracture criterion, package envelope verification, cost, and weight. The team also considered manufacturing methods and tooling when minimizing material costs. The deliverables are the material recommendations and topology optimizations for the three parts, an associated analytical modeling tool created with simulation software, and an evaluation of performance, manufacturability, and cost considerations.