Structural Optimization of an Air Shroud

Finding the right balance between structure mass and geometry design has become of major importance in order to insure optimum product lifetime and cost. So, based on a plastic air shroud used in automotive engine cooling systems as object of study, this work shows a process that allows to find an optimized structure shape and adjust its thicknesses to guarantee the desired mechanical performance with a minimum mass, always taking into account the thickness range recommended for the injection process. The shroud is submitted to a dynamic load under a given frequency in which it must not present resonance. This behavior is represented in a finite element model through normal modes results. Finally, geometric parameters got from this experience can help designers to start future projects focused on the results that really make the difference concerning the mechanical behavior.