Çetin, Mert

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01. Izmir Institute of Technology
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  • Master Thesis
    Design and Optimization of Shaft Bracket of Drum Brake for Heavy Duty Vehicle
    (01. Izmir Institute of Technology, 2021) Çetin, Mert; Artem, Hatice Seçil; Çetin, Mert; Artem, Hatice Seçil; 01. Izmir Institute of Technology; 03.10. Department of Mechanical Engineering; 03. Faculty of Engineering
    The automotive industry is one of the leading sectors with a wider market share than any other sector which can quickly adapt to the increasingly competitive environment. However, in addition to the increasing product costs, regulations aiming to reduce fuel consumption and carbon emissions require an optimal design that satisfies design requirements depending on seriously increasing competition in this sector. This situation aims to design lightweight and high-performance vehicle products in a shorter period. In this sense, optimization methods have become very popular especially with the development of computer technologies in recent years. Therefore, they are often preferred in the design of vehicle products which enable to achieve the most suitable design for the specified purpose in a short time. This thesis study aims to realize a new shaft bracket design to be used in Z-Cam drum brakes of heavy duty vehicles by optimization methods. In line with this goal, firstly, the boundaries of material distribution in the given design space for vehicle axle application were obtained with the help of topology optimization. Then shape optimization was applied to bring material distribution having the suitable rough surfaces into the manufacturable form. Here, the Solid Isotropic Microstructure with Penalization (SIMP) algorithm was used for topology optimization and Response Surface Method (RSM) for shape optimization. Finite element analysis (FEA) of the final design obtained due to optimization was repeated and design verification tests were performed on the shaft bracket prototype manufactured according to the final design. The effectiveness and applicability of the optimization method used in the study were examined by comparing the performed test results with the final FEA. As a result of this study, a lighter design having a 72% weight advantage was obtained instead of the existing shaft bracket and the new design showed the similar structural strength compared with the existing shaft bracket as a result of experimental verification tests. Consequently, it has been seen that the optimization methods are very effective for the structural design of vehicle products.