The challenge

SmartCAE developed a structured simulation workflow that transformed the initial unribbed housing into a fully optimized and validated structural design.
The first stage involved the creation of a simplified finite element model in which the design space available for optimization was carefully defined, excluding internal clearances, functional interfaces, and non-modifiable regions. Topology optimization was then performed with stiffness as the primary objective while incorporating manufacturing constraints representative of the casting process. This ensured that the optimization results were not only mathematically optimal but also directly applicable to production.
The resulting material distribution was interpreted and converted into an engineering-ready rib layout compatible with manufacturing requirements and assembly interfaces.
A second, high-fidelity finite element model was subsequently developed, introducing realistic contact interactions, bolt preload conditions, and representative loading at the bearing seats. This detailed analysis identified local stress concentrations, guided targeted design refinements, and verified the complete assembly for stiffness, static strength, fatigue life, and bolted joint integrity before final release for industrialization.

Our contribution

The simulation-driven workflow enabled the customer to replace traditional trial-and-error design iterations with an objective engineering process based on structural optimization and progressively refined CAE validation.
By identifying the optimal rib configuration early in the development process, the risk of discovering structural issues during prototype testing—or after tooling release—was significantly reduced, resulting in shorter development times and lower engineering costs.
The optimized design achieved an effective balance between stiffness, weight, and manufacturability while fully respecting the constraints of the casting process. Moreover, the integrated verification of contacts, bolt preloads, and operational loads provided confidence in the structural integrity of the complete assembly throughout its service life, including fatigue performance.
The result was a robust, production-ready transmission housing with improved structural efficiency, reduced technical risk, and a faster path to industrialization.

Benefits for the client

By relying on SmartCAE for this type of activity, the client benefits from a faster and more robust decision-making process, as geometric choices are not driven by successive trial-and-error iterations, but by a combination of structural optimization and progressively more realistic CAE assessments. This approach reduces the risk of identifying critical issues only during the prototyping stage or, even worse, after drawings for tooling and molds have already been released, when modifications become slow and costly.

A “guided” rib design process makes it possible to achieve an effective balance between stiffness, weight, and manufacturability, while keeping the technological constraints typical of cast components and subsequent machining operations under control. In addition, the integrated assessment of contacts, preload conditions, and operating loads makes it possible to evaluate the behavior of the assembly as a whole, rather than of the individual component alone, thereby increasing product reliability and confidence in meeting requirements throughout its service life, including fatigue-related phenomena.

In summary, the main benefit is having a single engineering partner capable of translating complex structural requirements into consistent, verifiable design choices that are ready for industrialization.