Weight reduction

•Example: Optimized shapes of wall thickness of a crankcase

Standard design	•hofer weight-optimised solution

	Problem analysis	hofer solution
Failure because of inhomogeneous stress distribution	Problem analysis through simulation of the failure	•Systematic solution approach through FEM and expert analysis

•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

•