Abstract: Actual load, material characteristics and other
quantities often differ from the design values. This can cause worse
function, shorter life or failure of a civil engineering structure, a
machine, vehicle or another appliance. The paper shows main causes
of the uncertainties and deviations and presents a systematic
approach and efficient tools for their elimination or mitigation of
consequences. Emphasis is put on the design stage, which is most
important for reliability ensuring. Principles of robust design and
important tools are explained, including FMEA, sensitivity analysis
and probabilistic simulation methods. The lifetime prediction of
long-life objects can be improved by long-term monitoring of the
load response and damage accumulation in operation. The condition
evaluation of engineering structures, such as bridges, is often based
on visual inspection and verbal description. Here, methods based on
fuzzy logic can reduce the subjective influences.
Abstract: A finite element analysis (FEA) computer software HyperWorks is utilized in re-designing an automotive component to reduce its mass. Reduction of components mass contributes towards environmental sustainability by saving world-s valuable metal resources and by reducing carbon emission through improved overall vehicle fuel efficiency. A shape optimization analysis was performed on a rear spindle component. Pre-processing and solving procedures were performed using HyperMesh and RADIOSS respectively. Shape variables were defined using HyperMorph. Then optimization solver OptiStruct was utilized with fatigue life set as a design constraint. Since Stress-Number of Cycle (S-N) theory deals with uni-axial stress, the Signed von Misses stress on the component was used for looking up damage on S-N curve, and Gerber criterion for mean stress corrections. The optimization analysis resulted in mass reduction of 24% of the original mass. The study proved that the adopted approach has high potential use for environmental sustainability.