Value-Engineered Design Optimization of a Reinforced Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles.

The transition from metal to plastic in the design of engine mount brackets marks a pivotal step toward sustainable and value-driven automotive engineering. This study investigates the optimization of plastic engine mount brackets, focusing on material selection, structural performance, and alignment with NVH (Noise, Vibration, and Harshness) targets. Recycled polymer composites were chosen for their favorable mechanical properties, environmental resilience, and contribution to circular economy goals. The primary objectives were weight reduction, cost-effectiveness, and manufacturability, without compromising structural integrity or long-term durability. A combination of Finite Element Analysis (FEA), CAE-based durability simulations, modal analysis, and comprehensive vehicle-level validation was conducted to assess dynamic performance. Results demonstrated that the optimized plastic brackets not only satisfy critical natural frequency and durability requirements but also offer a sustainable and technically sound alternative to traditional metal designs. This advancement highlights the broader potential for implementing recycled materials in high-performance automotive applications, enhancing vehicle efficiency while reducing environmental impact. Keywords: Recycled Polymer Composites, Engine Mount Bracket, NVH Optimization, Finite Element Analysis, Value Engineering.