A research on structure optimization of engine mount bracket based on misuse working condition

In the development process of a passenger car, its engine mount bracket was broken under a misuse working condition. According to a preliminary judgment by macroscopic fractography, the rapid break of mounting bracket is caused by overloading in misuse condition. Based on this, a vehicle dynamics model is built to simulate the misuse condition, with the load on the bracket obtained and a corresponding structural strength check conducted. The results reveal that the mounting bracket does not meet the strength requirements, and the bracket risky position by analysis is consistent with that really happened. Finally a topology optimization is performed on the bracket with both misuse condition and 28 conditions for strength check commonly used. A sample part of optimized scheme for the bracket is produced and installed on real vehicle for field test with no break happened again. The research provides important references for the strength design of engine mount bracket. © 2016, Society of Automotive Engineers of China. All right reserved.