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"This paper presents the shape optimization of an
automotive universal joint, by simultaneously considering
manufacturing cost, maximum drivable joint angle and
part volume. Comprised of three main components - two
yokes and a cross trunnion - a universal joint is a linkage
used to transmit rotational motion from one shaft to
another when the axes are coplanar, but not coinciding. In
this research, universal joint designs are analyzed and
compared using a weighted sum of three objective
functions: minimization of machining cost, maximization
of adjoining shaft joint angle, and minimization of total
part volume. Part modeling and analysis is conducted
using the Finite Element Analysis package ANSYS and
optimization is implemented using MATLAB. The
results show Pareto frontiers for both the flange and weld
yoke, constructed using the Adaptive Weighted Sum
technique. These frontiers clearly illustrate the trade-off
between machining cost and joint angle; that is, to
increase the joint angle, a corresponding increase in the
cost of the part is required. It has been shown that
maximization of driveable joint angle requires a
simultaneous increase in machining cost of 4.4% and
2.7% for the flange and weld yoke, respectively."
[ANSYS Structural, version 9.0]
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