
Enhancing Engine Mount Design through Topology Optimization for Additive Manufacturing
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The recent advancements in additive manufacturing technologies, coupled with the implementation of topology optimization techniques, are decisively redefining the framework for the design and fabrication of mechanical components. In the present study, a commercial automotive engine mount was investigated through the application of the SIMP (Solid Isotropic Material with Penalization) topology optimization algorithm, as implemented in commercial software such as SolidWorks and nTop. The resulting optimized geometries exhibit a high degree of structural complexity, which can be feasibly manufactured only through additive manufacturing processes. The component was initially digitized using a structured light 3D scanner, and its structural integrity was evaluated via finite element analysis (FEA). Following this, a topology optimization study was performed, and the structural response of the optimized design was reassessed. The topology optimization process led to a mass reduction of approximately 30%. Although the von Mises stresses increased by about 30%, the maximum displacement remained effectively constant. Beyond the conventional solid-body optimization, additional studies were conducted on the original design, replacing the internal solid volume with a gyroid lattice structure as the infill pattern. This alternative design approach resulted in a total mass reduction of approximately 40%. A marginal 3% reduction in stress was observed, accompanied by a significant increase of about 50% in total displacement. The increased compliance of the lattice-reinforced structure may enhance its ability to dissipate vibrational energy, potentially improving its performance as an engine mount. Motivated by the need for more effective vibration damping, a subsequent study was conducted incorporating an auxetic re-entrant lattice structure as the internal infill. This configuration exhibited improved mechanical performance, particularly in terms of damping behaviour and energy absorption