Optimization of a Phenolic Power Steering Pulley

For the American Automotive Industry to remain competitive, continued technological advances through application modelling and optimization are necessary. Ford Motor Company, in conjunction with The Durez Division of Occidental Chemical Corporation and Altair Engineering, applied this strategy to a phenolic power steering pulley which has been in production since 1985.

An optimized Finite Element Analysis model was developed resulting in a primary phenolic mass reduction of over 30% while still meeting the performance requirements. There were also a number of secondary system effects that evolved from the model process.